Container apparatus and method for using the same

ABSTRACT

A container apparatus is disclosed that can utilize a “buffer zone” between a highly moveable lid and a substantially stationary body. A collection of score lines substantially surrounding a plate can mediate between the mobile lid and stationary body. Flaps and accompanying side score lines can act collectively with the plate to facilitate the opening and closing of the lid. Opening and closing the lid can involve the folding of the various score lines in the buffer to various degrees.

RELATED APPLICATIONS

This continuation-in-part utility patent application claims priority toand incorporates by reference the following patent applications in theirentirety: (1) the provisional patent application titled “PRODUCTCONTAINER CUP WITH A FOLD-DOWN HINGED LID” (Ser. No. 61/161,112) thatwas filed on Mar. 18, 2009; (2) the utility patent application titled“CONTAINER APPARATUS WITH A BODY, PLATE, AND LID” (Ser. No. 12/725,061)that was filed on Mar. 16, 2010; (3) the provisional patent applicationtitled “CONTAINER APPARATUS AND METHOD FOR USING THE SAME” (Ser. No.61/416,292) that was filed on Nov. 22, 2010; (4) thecontinuation-in-part utility patent application titled “CONTAINERAPPARATUS AND METHOD FOR USING THE SAME” (Ser. No. 13/080,912) that wasfiled on Apr. 6, 2011; (5) the provisional patent application titled“CONTAINER APPARATUS AND METHOD FOR USING THE SAME” (Ser. No.61/577,084) filed on Dec. 18, 2011; and (6) the provisional patentapplication titled “CONTAINER APPARATUS AND METHODS FOR USING ANDMANUFACTURING THE SAME” (Ser. No. 61/664,130) filed on Jun. 25, 2012.

BACKGROUND OF THE INVENTION

The invention relates generally to containers. More specifically, theinvention is a container apparatus (the “container”), a method for usingcontainers, and a method of manufacturing containers.

Examples of containers include cups for hot beverages (such as coffee,hot chocolate, tea, etc.), cups for non-heated beverages (such as milk,juice, water, soda, etc.), containers for food products (such as icecream, soup, yogurt, solid foods, etc.), and containers for non-food orbeverage products (such as office suppliers, medical devices, etc.).

Containers are an important part of the modern economy. Many productscannot be stored, transported, sold, and/or used without first beingsecured in some type of container. Some types of products, such as manytypes of food products and virtually all beverage products, require sometype of container for the product to be handled or consumed. In manycontexts, the container is an integral part of how users “experience”the contents of the container. For example, in drinking a beverage, ahuman being often positions the beverage by positioning the cup thatcontains the beverage. Containers can also contribute to environmentalwaste after their utility has ended.

Different types of products require different types of containers anddifferent types of containers can have different purposes. Containerscan be used to (1) protect the contained product; (2) protect users inutilizing the product; (3) facilitate the ability of users to experiencethe product; (4) shape the way users experience a product; (5) impactthe ways in which users view the product; and (6) combinations of(1)-(5) above. In the context of a coffee cup, the container serves toprevent the inadvertent disbursement of the coffee and in doing soprevents hot coffee from being spilled on the user.

In meeting the needs of users, it is important to consider the feedbackloops between the contents of the container and the container itself.The attributes of a product will often impact the attributes of thecontainer used to house the product, and vice versa. For example, acontainer for a beverage product will typically need to be watertightwhile a container used for storing office supplies need not bewatertight or even fully enclosable. Similarly, a container suitable foruse in the context of sterilized medical supplies will have differentattributes than a container used to store spare change or golf tees.Even relatively similar types of products can involve different types ofcontainers. For example, at a quick service food restaurant, differenttypes of cups are used to hold juice, milk, coffee, and soda because ofthe different attributes that pertain to those products. Differentbeverages have different attributes, and those different attributes canmerit containers possessing different attributes.

Consumers have increasing expectations with regards to the usability andconvenience of the containers that they interact with. Differentcontainers can also have different anticipated users possessingdifferent skill levels and even different physical capabilities. Theproper usage of a container can vary widely depending on whether or notthe anticipated user of the container is a consumer. For example, abeverage container used in restaurants will need to be suitable for useby individual consumers, a wide cross section of the population thatincludes persons with disabilities as well as individuals of belowaverage physical and mental capabilities. In contrast, a container usedby locksmiths or mechanics to store their tools can utilize far morecomplex designs and operating procedures.

The intended lifespan of a container can be a significant variable inthe selection and design of a container. Many containers are disposed ofafter a single use. For example, a cup of ice cream sold in a grocerystore or drug store is intended to be thrown away after the contents areconsumed by a consumer. In contrast, a thermos can be emptied and filledover a lifetime of years or even decades.

Disposable containers can raise substantial environmental issues if thecontainers, or even just portions of the container, are notbiodegradable. Many such containers end up as litter that is both aneyesore and damaging to the environment. For example, the “Great PacificGarbage Patch” (which is also often referred to as the “Pacific TrashVortex”) is made up of high concentrations of plastics and other debristrapped by the currents of the North Pacific Gyre. Whether or not thesize of the Pacific Trash Vortex is currently as large as the state ofTexas, there is no disputing the fact that the area is large and thatthe damage to that area is significant. Moreover, there are four otherlarge places in the world's oceans where winds trap floating debris.Plastic lids for a paper cups and plastic water bottles exist far longeras waste than they do as useful consumer articles. A consumer typicallyenjoys a cup of coffee in a sitting lasting between 20 and 30 minutes.That lid can require years, decades, or even centuries to fullydecompose.

Billions of plastic bottles end in U.S. landfills each year. If thosebottles are laid end-to-end, there are enough plastic bottles disposedof each year to circle the equator hundreds of times over or to reachthe moon and back multiple times. As the population in developedcountries grows and as less economically advanced nations groweconomically, the environmental impact of disposable containers willonly increase.

Old habits die hard, and it is difficult to change the technical,business, and consumer expectations with regards to disposablecontainers. The business constraints on the manufacture of disposablecontainers such as paper cups are quite restrictive. The incrementalcost per container must be minimized to the extreme while minimizingwaste and satisfying quality requirements. The focus is on shavingcosts, not in the making of fundamental design changes. The high volumeand low margin aspects of container manufacture are coupled withexpensive tooling and other startup costs. Potentially innovativedesigns are often too expensive to effectively manufacture. In manyinstances, innovative designs are literally impossible to manufacture ona mass-production basis. The aggregate incentives and constraints onmanufacturers is a strong disincentive for product innovation. Theunderlying economics of such disposable containers coupled withmanufacturing limitations affirmatively teach away from innovativecontainer designs. Preconceived notions relating to disposable cupsproduced with paperboard further serve to stifle innovation by teachingaway from potential advances.

Consumer expectations also impede innovative changes to disposablecontainers. There are thousands of coffee shops and other retail outletsin the U.S. who collectively sell millions of coffee servings each yearwith paper or Styrofoam cups that utilize conventional plastics lids. Itwould be desirable for better containers to be used in conjunction withcontained products. However, most purchasing decisions are basedprimarily on the product, not the container. This basic and simple truthhas unfortunate ramifications because consumer demand not only fails toencourage innovation, but can also affirmatively impede substantialinnovations in container design. It is no accident that the conventionalpaper cup has changed very little over the course of recent decades.Consumers are used to the way things are, and in many instances,consumers are oblivious to container-related attributes and theirimplications.

The combined impact of design limitations, manufacturing constraints,and the economic reality of razor thin margins serve to lock in thestatus quo when it comes to the design of disposable containers. Manyaspects of the various container configurations described below arecounter-intuitive to those in the business of designing and makingcontainers.

In solving the problem of the plastic lid on disposable containers, amethod of manufacture relating to paperboard-related products has beeninvented.

SUMMARY OF THE INVENTION

The invention relates generally to containers. More specifically, theinvention is a container apparatus (the “container”), a method for usinga container, and a method of manufacturing the container.

The container can be implemented in a wide variety of differentembodiments for use with a wide variety of different contents in a widevariety of different operational contexts. Examples of containersinclude cups for hot and not-hot beverages (coffee, milk, juice, water,soda, etc.), containers for food products (ice cream, soup, yogurt,solid foods, etc.), and containers for non-food or beverage products(office suppliers, medical devices, etc.). Different embodiments can beadapted to contain different types of products and user experiences.Different embodiments can utilize a wide range of different materials.Some embodiments of the container can be reusable while others aredesigned to be disposable. Many disposable embodiments of the containerwill include paperboard as one of the materials.

The container includes a body and an attached lid. In many embodimentsof the container, the body and lid are intended to be permanentlyattached to each other. In other embodiments, the lid can be configuredin such a manner as to be removable.

Many embodiments of the container are intended to allow for users toopen and/or close the container as opposed to merely access the contentsof the container while the container is in a closed state. Differentembodiments of the container can have different operating states orpositions.

Many embodiments of the container can include a plate located betweenthe body and the lid can be used to facilitate the opening and/orclosing of the lid. Some embodiments of the container will have onehinge while other embodiments of the container will have two hinges tofacilitate the opening and closing of the lid.

Despite the design and manufacturing preconceptions in the prior art,the containers described herein can be manufactured through the use ofmachine tools that are available in the prior art. No significantchanges are required “beneath the table” of the various prior artmachine tools, with some reconfigurations being made to tools above thetable. The techniques that can be used to mass produce the container canbe utilized to manufacture other articles, and are particularly usefulin the context of manufacturing paperboard-related products.

BRIEF DESCRIPTION OF THE DRAWINGS

It is not possible to visually illustrate all of the differentvariations of containers and container attributes. The followingdrawings do however illustrate different examples of various embodimentsof the apparatus and various innovative attributes that can beincorporated into containers:

FIG. 1 a is a diagram illustrating an example of rear plan view of anopen container that includes a plate.

FIG. 1 b is a diagram illustrating an example of a rear plan view of anopen container that does not include a plate.

FIG. 1 c is a diagram illustrating an example of a rear plan view of arectangular container that includes a plate.

FIG. 1 d is a diagram illustrating an example of an exploded view ofdifferent surfaces and score lines that can be incorporated into thecontainer.

FIG. 1 e is a diagram illustrating an example of an exploded view of aplate, a set of flaps, and various foldable score lines.

FIG. 2 a is a diagram illustrating an example of an elevated rear viewof a container in a fully closed state.

FIG. 2 b is a diagram illustrating an example of an elevated rearperspective view of a container in a fully closed state except for anopen tab passageway.

FIG. 2 c is a diagram illustrating an example of an elevated rear viewof a container in a partially open and partially closed state.

FIG. 2 d is a diagram illustrating an example of an elevated rear viewof a container in a fully open state.

FIG. 3 a is a flow chart diagram illustrating an example of a method foropening a container.

FIG. 3 b is a flow chart diagram illustrating an example of a method forclosing a container.

FIG. 4 a is a flow chart diagram illustrating an example of a method formanufacturing a container.

FIG. 4 b is a flow chart diagram illustrating an example of a method formanufacturing a container.

FIG. 5 a is a diagram illustrating an example of a top blank used in theprocess illustrated by FIG. 4 a.

FIG. 5 b is a diagram illustrating an example of a bottom blank used inthe processes illustrated by FIG. 4 a and FIG. 4 b.

FIG. 5 c is a diagram illustrating an example of a lid blank used in theprocess illustrated by FIG. 4 b.

FIG. 5 d is a diagram illustrating an example of a sidewall blank usedin the process illustrated by FIG. 4 b.

FIG. 6 a is diagram illustrating an example of a plan view of the bottomportion of container with the internal cavity illustrated with dottedlines.

FIG. 6 b is a geometric diagram illustrating an example of a relativelylarge rim arc with respect to the body hinge.

FIG. 6 c is a geometric diagram illustrating an example of a relativelysmall rim arc with respect to the body hinge.

FIG. 6 d is a diagram illustrating an example of a plate that has flaps.

FIG. 6 e is a diagram illustrating an example of a plate that has skidlocks.

FIG. 6 f is a diagram illustrating an example of a plate with a hingebreak.

FIG. 6 g is a diagram illustrating an example of a top plan view of alid with chevrons.

FIG. 6 h is a diagram illustrating an example of a top plan view of alid with a lid stiffener score line.

FIG. 6 i is a diagram illustrating an example of a top plan view of alid with a hinge break.

FIG. 6 j is a diagram illustrating an example of a top plan view of alid with flaps but no plate.

FIG. 6 k is a diagram illustrating a top view of a plate and flapconfiguration that forms a substantially continuous circular arc.

FIG. 7 a is a geometric diagram illustrating an example of asubstantially circular primary score line comprised of a substantiallycircular inner groove and a substantially circular body hinge.

FIG. 7 b is a geometric diagram illustrating an example of asubstantially circular primary score line comprised of a substantiallycircular inner groove and a substantially straight body hinge.

FIG. 7 c is a bottom plan view diagram illustrating an example of acontainer with the primary score line illustrated in FIG. 7 a.

FIG. 7 d is a bottom plan view illustrating an example of a containerwith the primary score line illustrated in FIG. 7 b.

FIG. 7 e is a diagram illustrating an example of a top plan view of alid.

FIG. 7 f is a diagram illustrating an example of a rear plan view of abody of a container in a cylindrical shape.

FIG. 7 g is a diagram illustrating an example of a rear plan view of abody of a container in a substantially elliptical shape.

FIG. 8 a is a diagram illustrating an example of a side plan view of acontainer in a fully open position.

FIG. 8 b is a diagram illustrating an example of side plan view of acontainer being moved from a fully open position.

FIG. 8 c is a diagram illustrating an example of a side plan view of acontainer in a fully closed position

FIG. 8 d is a diagram illustrating an example of portion of a body thatincludes a rim and an inner groove

FIG. 8 e is a diagram illustrating an example of an inner groove angle.

FIG. 8 f is a diagram illustrating an example of a front plan view of acontainer in a fully closed position.

FIG. 8 g is a diagram illustrating an example of a tab moving from aclosed position to an open position.

FIG. 9 a is a perspective diagram illustrating an example of how skidlocks can facilitate the stacking of containers in a fully closedposition.

FIG. 9 b is a perspective diagram illustrating an example of stack ofcontainers in fully open positions.

FIG. 9 c is a diagram illustrating an example of a side plan view of astack of containers in fully open positions.

FIG. 10 a is a flow chart diagram illustrating an example of a methodfor manufacturing a container.

FIG. 10 b is a flow chart diagram illustrating an example of a methodfor manufacturing a container.

FIG. 10 c is a flow chart diagram illustrating an example of a methodfor manufacturing a container.

FIG. 10 d is a flow chart diagram illustrating an example of a methodfor manufacturing a container.

FIG. 10 e is a diagram illustrating an example of a bottom portion of asidewall blank being wrapped around a bottom.

FIG. 10 f is a diagram illustrating an example of curled bottom blankskirt.

FIG. 10 g is a diagram illustrating an example of a finished, knurled,and squared bottom.

FIG. 10 h is a diagram illustrating an example of a machine tool thatcan be used to perform many of the processes identified in FIG. 10 d.

FIG. 11 a is diagram illustrating an example of a sidewall blank thatincludes two groupings of dimples.

FIG. 11 b is a diagram illustrating an example of a container with abody wall substantially covered in dimples.

FIG. 11 c is cross section diagram of a body wall with dimplesprotruding outward from the container.

FIG. 11 d is a cross section diagram of a body wall with dimplesprotruding inward towards the cavity of the container.

FIG. 11 e is a cross section diagram of a body wall with dimplesprotruding both inwards towards the cavity of the container and outwardtowards the external environment of the container.

DETAILED DESCRIPTION

The invention relates generally to containers. More specifically, theinvention is a container apparatus (the “container”), a method for usingcontainers, and a method for manufacturing containers.

I. OVERVIEW OF DIFFERENT CONTAINER EMBODIMENTS

FIGS. 1 a, 1 b, and 1 c illustrate examples of back plan views ofdifferent containers 20. In FIGS. 1 a, 1 b, and 1 c a lid 28 is shown asattached to a body 22 of the container 20 even while the container 20 isin a fully open operating state.

The container 20 can be implemented in a wide variety of differentshapes and operating configurations. Different embodiments of thecontainer 20 can involve a wide variety of different componentscomprised of a wide variety of different materials. Differentembodiments of the container 20 are suited for different types ofcontents.

A. Non-Aseptic Cup

FIG. 1 a is a diagram illustrating an example of rear plan view of anopen container 20 that includes a plate 24. The container 20 in FIG. 1 ais intended for use as a non-aseptic container for beverages such ascoffee, water, soda, and other similar beverages. The container 20includes a body 22, a lid 28, and a plate 24 between the lid 28 and thebody 22. The plate 24, along with the body hinge 56 and plate hinge 26serve to facilitate the transition of the container 20 from a fully openoperating state to a fully closed operating state. A non-aseptic cupcontainer 20 can be implemented in both disposable and non-disposableembodiments. A disposable embodiment of the container 20 in FIG. 1 a canbe comprised primarily of paperboard. Score lines, cuts, rolls, andother attributes can be implemented into the container 20. Adhesives andcoatings of non-paperboard materials can also be used to reinforce thestructure of the container 20. In many embodiments, such materials areapplied exclusively to the exterior surfaces of the container 20 so thatthe beverage in the container 20 does not come into contact with thosematerials. As illustrated in FIG. 1 a, the container 20 also includestwo flaps 54, one on each side of the plate 24. Non-aseptic embodimentsof the container 20 that are curved or are even substantiallycylindrical in shape (such as a cup) may benefit from having curved sidescore lines 55 between the plate 24 and flaps 54, and a curved bodyhinge 56.

The non-aseptic container 20 illustrated in FIG. 1 a can be implementedin both disposable and non-disposable embodiments. Whether or not aparticular embodiment is disposable will be primarily impacted by thematerial composition of the container 20. Different embodiments of thecontainer 20 can include many elements not illustrated in FIG. 1 a thatare discussed below and illustrated in subsequent figures.

B. Aseptic Cup

FIG. 1 b is a diagram illustrating an example of a rear plan view of anopen container 20 that does not include a plate 24.

The container 20 can be implemented to function as an aseptic container20 for beverage products. Common examples of beverages requiring asepticcontainers 20 are milk and juice. Many disposable aseptic containers inthe prior art as well as the aseptic container 20 of FIG. 1 b areconfigured to be filled before it is aseptically sealed. Thus, thecontainer 20 of FIG. 1 b is not necessarily intended to be opened andclosed repeatedly as the container 20 of FIG. 1 a is configured tofunction. As a result, the container 20 of FIG. 1 b need not include aplate 24 or a plate hinge 26. The other noticeable difference betweenFIG. 1 a and FIG. 1 b is that FIG. 1 b discloses a flange 59 toaseptically seal the contents of the container 20. In some embodiments,the flange 59 will include score lines that bisect the edge of theflange. In other embodiments, there the flange 59 can includedifferently oriented score lines or no score lines whatsoever. Thefunctionality of the flange 59 can be assisted by incrementally reducingthe amount of material in the flange 59 as edge of the flange isapproached.

Although not visible from the drawings, the aseptic container 20 of FIG.1 b will typically require different materials than the non-asepticcontainer 20 of FIG. 1 a. Aseptic containers 20 will be comprised ofcombinations of paperboard, aluminum foil, metalized film, ethyleneacrylic acid, low-density polyethylene, nylon, polystyrene,polyvinylidine chloride, ethylene vinyl alcohol, and/or other suitablematerials. The method of manufacturing an aseptic container 20 will alsodiffer from the method used to manufacture a non-aseptic container 20.Aseptic containers 20 involve sterilization steps as various points inthe process.

The container 20 illustrated in FIG. 1 b is intended primarily fordisposable use. However, depending on the materials use, the container20 can be implemented to support reusable use. Such embodiments willneed to use a sealing mechanism different than the flange 59 illustratedin FIG. 1 b. Different embodiments of the container 20 can include manyelements not illustrated in FIG. 1 b that are discussed below andillustrated in subsequent figures.

C. Other Container Embodiments

FIG. 1 c is a diagram illustrating an example of a rear plan view of arectangular container 20 that includes a plate 24.

The container 20 is not limited to beverage products or even to productswhich are intended to be ingested or imbibed by human beings or otherforms of living beings. Different embodiments of the container 20 caninvolve vastly different shapes, sizes, and materials. As illustrated inFIG. 1 c, such containers 20 can have lid 28 attached to a plate 24 thatis attached to a body 22. The parameters of the plate 24 are outlined bythe body hinge 56 and the plate hinge 26.

Different containers 20 can involve different methods of use and bemanufacturing using different manufacturing processes.

II. CONTAINER ATTRIBUTES

A container 20 can be defined with respect to a variety of differentattributes. Some of those attributes are discussed below.

A. Contents

Different embodiments of the container 20 can be used for the storage,transportation, and/or use of a wide variety of different products. Acontainer 20 can be used to store a wide range of different foodproducts and beverages, paper money and coins, office supplies,electronics components, tools, chemical products, cleaning detergents,fabric softeners, animals, and virtually anything else for the purposesof containment, storage, and/or transportation. Virtually any type orcombination of solid, liquid, or even in certain circumstances, gasproduct can benefit from the use of a container 20. Some types ofcontents must be removed from a container to be accessible to the userof the contained item while in other instances such as with many liquidproducts, the container 20 is the means by which a user controls thecontents of the container 20.

The configuration of a particular container 20 will depend on theintended contents of that container 20. For example, some embodiments ofthe container 20 can be configured for the purposes of storingbeverages, food products, medicinal products, or other items intended tobe ingested by a human being or other living being. A container 20 foringested items will have different operating requirements than acontainer 20 for non-ingested items. Some containers 20 may need tostore hot liquids such as coffee while other embodiments may need tostore cold solids such as ice cream as well as cold liquids such asmelted ice cream. In some instances, the contents of a container 20 mustbe kept dry while in other embodiments the contents of the container 20are damp or even inherently wet.

B. Shape

Different embodiments of the container 20 can have widely differentshapes. A variety of different factors can individually or incombination with other factors impact the shape of the container 20.Examples of potential factors can include but are not limited to thecontents of the container 20, ease of use, material composition of thecontainer 20, operating requirements of the container 20, cost concerns,user expectations, durability requirements, transportation issues(including the ability to be effectively stacked), durability, andmanufacturing constraints.

For example, in the context of a cup, the container 20 is likely to becylindrical in shape or at least substantially cylindrical in shape asis illustrated in FIGS. 1 a and 1 b. This is due primarily to userexpectations and ease of use. In other contents, a rectangular box shapeas illustrated in FIG. 1 c is the most desirable shape. As illustratedin FIGS. 1 a and 1 b, many embodiments of cup containers 20 will besubstantially cylindrical in shape rather than cylindrical in shapebecause the bottom portion of the container 20 will be slightly smallerthan the upper portions of the container 20. This is to facilitate theability to stack such containers 20 while they are in open and unfilledstates.

As discussed below, the shape of the container 20 can also be impactedby the operating state of the container 20. For example, manyembodiments of the container 20 will have a circular or substantiallycircular horizontal cross-sectional shape when the container 20 is an afully open position, i.e. when the lid 28 is fully upright asillustrated in FIGS. 1 a, 1 b, and 1 c. The shape of such a container 20when in a closed or partially closed state can become less circular andmore elliptical in shape. The change in shape results from the motion ofthe lid 28, the plate 24, and portions of the body 22 in the opening andclosing of the container 20. The doubled hinged architecture (seeelements 26 and 56) of a container 20 is complicated by the curved shapeof the container 20. Most examples of hinges in the prior art involvestraight hinges.

In many embodiments, the shape of the container 20 and the shape of theinternal cavity 46 of the container 20 will mirror each other. Forexample, in the context of a coffee cup, the internal cavity 46 willoften be substantially cylindrical in shape. In some embodiments, thegeometry of one or more cavities 46 within the container 20 can have asubstantially different geometric shape than the container 20.

C. Lifespan

The container 20 can be implemented in ways that are consistent withongoing non-disposable use, but many embodiments of the container 20will be configured for disposable embodiments. The desired lifespan of acontainer 20 can also be influenced by the intended lifespan of thecontents of the container 20 and the typical context of when a container20 is loaded with its contents. For example, the cup in FIG. 1 a isintended for use in an environment where the cup is filled by the userof the cup (or a service provider serving the user). This is the typicalcontext for soft drinks, coffee, tea, and other drinks. By contrast, thecup in FIG. 1 b is an aseptic container 20 that is filled and sealedprior to being distributed for consumption by users.

The innovative aspects of the container 20 may be most beneficial in thecontext of disposable containers 20 because disposable containers 20raise the most significant environmental concerns due to the sheernumber of such containers 20. For example, the number of disposable cupsused and discarded each day is truly staggering. The high volume of suchcontainers 20 coupled with the disposable nature of disposablecontainers also serves to make them extremely cost sensitive componentsin an efficient supply chain.

D. Material Composition

Different embodiments of the container 20 can be comprised of a widevariety of different materials. The container 20 was originally designedfor use in the context of paper or paperboard disposable cups. However,different materials can be used For example, in the context of acontainer 20 serving as a cup the cup could be comprised of paper,paperboard, stainless steel, metal, ceramics, plastics, or other typesof materials. Different types of coatings such as polymer coatings, highbarrier polymer coatings (including but not limited to high carriersilver coatings), polyethylene coatings (including but not limited topolyethylene terephthalate coatings), biopolymer coatings (including butnot limited to polylactide polymers), biodegradable polyester, and othertypes of coatings can be used with respect to the container 20. Any ofthe materials discussed above with respect to aseptic containers 20 canalso be used to reinforce the structure of a container 20 that is notaseptically sealed.

In many disposable embodiments of the container 20, the container 20will be primarily comprised of paperboard or some similar material, butparticular portions of the container 20 may be reinforced with one ormore coatings.

Different material compositions for containers 20 can influence thedifferent ways in which the different aspects of the containers 20 areshaped. For example, embossing (raising the material), debossing(recessing the material), stamping, folding, and cutting can be used tomachine a container 20 comprised of paper, paperboard, or othermaterials. Such structural attributes can be critical to thefunctionality of the container 20, but such attributes can also be verymuch constrained by the manufacturing constraints involved inimplementing certain design features.

Many disposable containers in the prior art involve plastic lids. Suchlids are not typically biodegradable and they require significantquantities of oil for their production. Such lids are used once, oftenfor mere hours or even minutes, and then spend decades in landfills oras floating debris in the ocean. The container 20 can be implemented insuch a way as to be just as reliable as prior art containers, whilebeing less expensive and less environmentally damaging at the same time.

The material composition and attributes of the container 20 can also beimpacted by requirements relating to thermal insulation

E. Thermal Insulation

Different containers 20 may involve vastly different operatingparameters relating to temperature. Coffee and soup are served hot,while ice cream and frozen yogurt are served cold. The temperature ofthe contents within the container 20 can impact the lifespan of thecontainer 20 as well as the ability of the container 20 to satisfy theneeds its users.

Some embodiments of the container 20 will include dimples 31 or evendimple groups 33 to insulate the user of the container 20 from thetemperature of the contents of the container 20. Dimples 31 can extrudeoutwards toward the external environment of the container, inwardtowards the cavity 46 of the container, or in both directions.

Dimples 31 and dimple groups 33 serve can serve as a built in “sleeve”for coffee drinkers who would otherwise require an additional separatesleeve in order to enjoy their beverage. Sleeves could also memanufactured to include such dimples 31 and dimple groups 33.

The heat-flow attributes of a container 20 can also be impacted throughthe use of multiple-wall 42 configurations, the ventilation of thecontainer 20, and the material composition of the container 20.

F. Ventilation

Different containers can have different air flow requirements. The samecontainer 20 may have different requirements in different contexts. Forexample, while an aseptic container 20 containing juice or milk isclosed and sealed, it should be essentially air tight for sanitationreasons. However, in the drinking a beverage from a container 20, thereare ventilation and pressurization requirements to allow the beverage toflow out of the container 20 consistent with user expectations.

In the context of non-aseptic containers 20, desirable horizontalventing can be achieved through ventilation gaps 29. Some embodimentswill use a cover 27 shaped in such a manner to allow a beverage productto be ventilated immediately prior to being imbibed by the user,preventing the user from being injured by a drink that is too hot tosafely consume.

A rim 34 with a serrated edge can also enhance the ventilation of thecontainer 20 and its contents.

G. Flexibility/Rigidity

The attributes of flexibility and structural rigidity are important inthe context of a paperboard container 20 in which a lid 28 is integralto the body 22 of the container 20. In moving the lid 28 between an openand closed operating state, certain portions of the container 20 willneed to be flexible to permit repeated movement between the variousoperating states. Simultaneously, other aspects of the container 20 willneed to be sufficiently rigid to sustain the structural integrity of thecontainer 20 while certain portions of the container 20 are beingflexible.

The attributes of flexibility and rigidity are discussed in greaterdetail below with regards to operation states of the container 20.

H. Components and Component Configurations

As illustrated in FIG. 1 d, many elements of the container 20 can bedescribed in terms of being a surface 75 or being a score line 70. Thecore surfaces 75 of the container 20 can include a body 22, a lid 28,and a plate 24 that serves as an interface between the body 22 and thelid 28. Many of the boundaries between these different surfaces 75 aremarked by score lines 75.

In many embodiments of the container 20, all or substantially all of thecomponents of the container 20 are integral with the container 20 andare not designed to be removable from the container 20. Whatdistinguishes the boundaries of different components or surfaces 75 insuch embodiments can include: geometric shapes and dimensions; relativepositions within the container 20; function; relative movementcapabilities; and embosses, debosses, score lines, and other types offolds, grooves, cuts, serrations, etc, (collectively “score lines”).

Score lines 70 can be divided into two categories. A foldable score line71 is a score line that bends or folds to facilitate the movement of thelid 28. In contrast, a non-foldable score lines 72 is a score line thatreinforces the structural integrity of a particular surface. Asillustrated in FIG. 1 d, a plate hinge 26 acts as a hinge between thelid 28 and the plate 24 and a body hinge 56 acts as a hinge between theplate 24 and the body 22. The container 20 utilizes a double-hingedarchitecture with two foldable score lines 71 serving as two hinges thatsurround the plate 24. FIG. 1 e adds two side flaps 54 to thatconfiguration, with a side score line 55 connecting each flap 54 to theplate 24 and a flap bottom score line 57 connecting each flap 54 to thebody 22 of the container 22. The body hinge 56, plate hinge 26, sidescore line 55, and flap bottom score line 57 are each examples offoldable score lines 71 because they are intended to be bent or foldedto facilitate the opening and closing of the lid 28. Examples ofnon-foldable score lines 72 are discussed below, such as a verticalcrease 25, a support score line 38, a tab base score line 48, a coverscore line 60, and a stiffener score line 63,

The container 20 can be implemented in a wide variety of differentcomponent configurations. The container 20 includes a body 22, a lid 28,and a body hinge 56. All other components of the container 20 areoptional, depending on the particular embodiment.

In many embodiments of the container, the body 22 and the lid 22 areintended to be permanently integral with each other. In otherembodiments, the user 20 may have the option of either temporarily orpermanently removing the lid 22.

Many embodiments of the container 20 (see FIGS. 1 a and 1 c) will alsoinclude a plate 24 that serves as an interface between the lid 28 andthe body 22. Many of embodiments of the container 20 (see FIGS. 1 a and1 b) will include flaps 54 located near the base of the lid 28 thatassist the user to seal the lid 28 in a closed position. Embodiments ofthe container 20 that are configured to be filled and sealed prior tobeing provided to users (such as aseptic containers 20 containingproducts such as juices) can include a flange 59 that is used to sealthe container.

Although not illustrated in any of the Figures, a container 20 notdesigned to be filled by users can include both a plate 24 and a flange59.

I. Operating States

Containers 20 serve to selectively contain and selectively makeaccessible the contents of the container 20. Different containers 20will have different operating states, different openings being capableof open or closed, and different components that will involved intransitioning from one operating state to another.

The container 20 has a lid 28 for opening and closing the container 20.Thus, each container 20 will have at least two or more operating states.The plate 24, flaps 54, tab(s) 30, passageway(s) 32, and potentiallyother components can individually possess operating states thattransition from open to closed or closed to open as the container 20 asa whole transitions from an operating state of a fully opened state to afully closed state, and vice versa.

FIG. 2 a is a diagram illustrating an example of an elevated rear viewof a container 20 in a fully closed state. The lid 28 is secured withinan inner groove 52 in the body 22, the opening 32 is blocked by the tab30, and the plate 24 and flaps 54 are in fully closed positions.

FIG. 2 b is a diagram illustrating an example of an elevated rearperspective view of a container 20 in a fully closed state except for anopen tab passageway 32. As discussed below, the passageway 32 (which canalso be referred to as an opening 32) allows a user to access thecontents of the container 22 while the lid 28 is still in a sealedposition. In the context of a cup, the passageway 32 can be used toinsert a straw, or the user can cause the contents to pour out thepassageway 32. In many embodiments, a horizontal cross section of thebody 22 in FIG. 2 b is substantially more elliptical in shape than theillustrating in FIG. 2 c.

FIG. 2 c is a diagram illustrating an example of an elevated rear viewof a container 20 in a partially open and partially closed state. Thelid 28 is no longer secured within the inner groove 52, and the flaps 54and plate 24 are neither substantially parallel with a bottom surface 40of the container 20 nor substantially straight up as when in a fullyopened operating state. In many embodiments, a horizontal cross sectionof the body 22 in FIG. 2 c is substantially more elliptical in shapethan the illustrating in FIG. 2 d.

FIG. 2 d is a diagram illustrating an example of an elevated rear viewof a container 20 in a fully open state, such as the containers in FIGS.1 a, 1 b, and 1 c. In many embodiments, a horizontal cross section ofthe body 22 in FIG. 2 d is substantially circular in shape or at leastsubstantially more circular in shape in comparison to the container inFIG. 2 b or even FIG. 2 c.

Operating states are discussed in greater detail below. Differentexamples of operating states are illustrated in the changes from FIGS. 2a-2 d. FIGS. 8 a-8 c discloses similar states from a different view.FIGS. 8 a-8 c are discussed below.

J. Using the Container

Different embodiments of the container 20 can involve a variety ofdifferent methods for opening and closing the container 20. Moreover, asidentified above and illustrated in FIGS. 2 a through 2 d, the container20 can possess more than two operating states. Different componentswithin the container 20 are capable of having opened, closed, orpartially opened/partially closed individual operating states.

There are a variety of different ways to open and close the container20. Different users may behave differently. For example, some users maytend to press down on the lid 28 to close the container 20 while otherusers may tend to press down on the plate 24. Similar variations may bepracticed in terms of opening the container 20.

1. Opening the Container

FIG. 3 a is a flow chart diagram illustrating an example of a method foropening a container 20. At 200, the edge 51 of the lid 28 is dislodgedfrom the inner groove 52 of the body 22. The process at 200 is analogousto the differences between FIG. 2 b and FIG. 2 c discussed above. At200, the process unseals the container 20 and permits the variouscomponents to move as they are configured to move.

At 202, the plate 24 and flaps 54 flex. The process at 202 isillustrated by the differences between FIGS. 2 b and 2 d.

At 204, the lid 28 is lifted into a straight up position as illustratedin FIGS. 1 a, 1 b, 1 c, and 2 d.

The loading or filling to the container 20 could occur while inpotentially any of the states identified above.

The closing/sealing process ends after the closing of the opening 32.

2. Closing the Container

FIG. 3 b is a flow chart diagram illustrating an example of a method forclosing a container 20. The process of FIG. 3 b can be characterized asthe process of FIG. 3 a, except in reverse.

At 206, the plate 24 and flaps 54 are flexed while the lid 28 remainssubstantially upright.

At 208, the lid 28 is pressed downward.

At 210, the edge 51 of the lid 28 is secured within the inner groove 52of the body 22.

Different users may close the container 20 applying pressure indifferent ways. For example, users could press down on the lid 28 or theplate 24 to initiate the closing process.

K. Manufacturing the Container

Different embodiments of the container 20 can utilize differentmanufacturing processes and different combinations of tooling. In someinstances, a single design of a container 20 can be manufactured in avariety of different ways. With respect to embodiments of the container20 comprised exclusively or primarily with some type of paper orpaperboard, the process of manufacturing the container 20 involvescreating blanks, flat two dimensional cutouts that are subsequentlyshaped and treated to ultimately form the container 20. Certain scorelines, coatings, and other processing may be performed on a blank, whileother processing can be performed after one or more blanks have beencombined and shaped.

1. Two Blank Configuration

FIG. 4 a is a flow chart diagram illustrating an example of a method formanufacturing a container 20 from two blanks. FIG. 5 a is a diagramillustrating an example a top blank 100 and FIG. 5 b is a diagramillustrating an example of bottom blank 102.

Returning to FIG. 4 a, at 212, a bottom blank 100 and a top blank 102are created.

At 214, the bottom blank 100 is fused together with the top blank 102 asthe container 20 is shaped into a cup.

The manufacturing process is described in greater detail below. In manyembodiments, all score lines except for the inner groove 52 and bodyhinge 56 are implemented prior to the securing of the top blank 102 tothe bottom blank 100. In other embodiments, all score lines can be addedas part of the blank preparation process that occurs prior to combiningthe blanks.

There are advantages to machining the body hinge 56 and inner groove 52after the blanks have been fused together and shaped. By doing so on theshaped and fused shell, the body hinge 56 can be implemented in theshape of a substantially curved arc rather than a straight line segment.A contrast of FIG. 7 a with FIG. 7 b illustrates this difference.

In FIG. 7 a, the curved body hinge 56 coupled with the inner groove 52together form a single score line 61 that encircles all or substantiallyall of a horizontal cross section of the body 22. In FIG. 7 b, the bodyhinge 56 is straight, impacting the overall shape of the score line 61.

It is counterintuitive that use of a circular tool to create a circularscore line (the combination loop 61 formed by the body hinge 56 andinner groove 52) is desirable, but such a process can be desirable andit can lead to superior results.

As discussed in greater detail below, a substantially circularcombination loop 61 as illustrated in FIG. 7 a (in contrast to the endsof a substantially circular inner groove 52 mating with the ends of asubstantially straight body hinge 56 as illustrated in FIG. 7 b) makethe container 20 more circular in shape when the container 20 is in afully opened state. This has useful features in terms of stackabilityand durability. However, the fact that such an implementation involves acircular or substantially circular body hinge 56 is a result that is nottaught in the prior art, and is counterintuitive to those of ordinary oreven superior skill in the applicable art.

By having the inner groove 52 and body hinge 56 machined as a singularcircular loop, the flexural strength and crush resistance of thecontainer 20 is enhanced as a result of the top to bottom compressionstrength. Various processing can be used to enhance the combination loop61 and further strengthen the overall structure of the container 20.

2. Three Blank Configuration

Although the container 20 can be manufactured using a two blankconfiguration as described above, there are advantages to using a threeblank configuration in which the loop 61 is machined into the container20 after a lid blank 104 and a sidewall blank 106 are fused together,and then shaped around the bottom blank 100.

As described above, the three blank configuration of FIG. 4 b can alsoinvolve machining the primary score line 61 comprising the body hinge 56and the primary groove 52 after the container 20 has been shaped into asubstantially cylindrical shape. In other embodiments, all score linescan be machined into the blanks prior to the process of fusing themtogether.

FIG. 5 c is a diagram illustrating an example of a lid blank 104 used inthe process illustrated by FIG. 4 b. FIG. 5 d is a diagram illustratingan example of a sidewall blank 106 used in the process illustrated byFIG. 4 b. Different embodiments of the container 20 can involvedifferent component configurations with many of those differencesmanifesting themselves in the blanks used to make the containers 20. Forexample, FIG. 5 c discloses vertical creases 25 to reinforce the lid 28of the container 20. A reinforcement member 23 is used to connect thelid blank 104 with the plate 24 of the sidewall blank 106, strengtheningthe container 20 as the container 20 is transitioned between open,semi-open/semi-closed, and closed operating states. FIG. 5 c alsoillustrates a cover 27 that is different than a tab 30. Other featuresthat may be highly desirable are the curved side flaps 55 and a flapangle 97 of between about 35 degrees and about 70 degrees.

There are several advantages to the 3 blank manufacturing process ofFIG. 4 b over the 2 blank manufacturing process of FIG. 4 a. The processdisclosed in FIG. 4 b can prevent lid staining and wicking. The lid 28can be better protected against humidity. Costs and waste is reduced byreducing the amount of scrap paper board that results because a threeblank configuration requires fewer sheets of paperboard than a two blankconfiguration.

FIG. 4 b is a flow chart diagram illustrating an example of a method formanufacturing a container 20 utilizing 3 blanks.

At 216 a sidewall blank 106 and a lid blank 104 are prepared.

At 218, the sidewall blank 106 and the lid blank 104 are fused togetherinto a fused blank.

At 220, a bottom blank 100 is prepared.

At 222, the fused blank is shaped into a shell around the bottom blank100.

At 224, the bottom blank 100 is secured within the bottom portion of theshaped shell.

The process of machining the score line 61 that comprises the body hinge56 and the inner groove 52 can be implemented at potentially any timeafter the lid blank 104 and the sidewall blank 106 are combined andshaped into the shape of the container 20. The shaping of the fusedblank typically happens in conjunction with insertion of the bottomblank 100.

The manufacturing process is described in greater detail below, Thecontainer 20 of FIG. 2A can be manufactured on a mass production andcost effective basis using substantially unmodified prior art machinetools. Utilizing the infrastructure provided below the table of suchtools, the desired modifications can be made to functionality providedabove the table. The ability to utilize prior art tools is a significantadvantage in terms of market penetration and the costs associated withthe production of containers 20.

L. Ancillary/Supplemental Functionality

Although containers 20 are used primarily with respect to thecontents-related (i.e. product-related) functionality, containers 20 canbe implemented in ways to serve additional functions.

Containers 20 can provide an excellent opportunity for businesses andother organizations to facilitate communications. In many instances, thecontainer 20 can include text, graphics, and other indicia tocommunicate brand identity, product information, marketing information,or public service announcements. As miniature electronic componentsbecome increasingly easy and inexpensive to incorporate into containers,some containers 20 can be configured to provide audio communicationsusing technology similar to that used to play music when someone opens agreeting card. A container 20 can also be configured to use poweredelectronics to flash lights or otherwise generate visual indicia. Forexample, a coffee cup 20 container could be configured to play a song,flash a light, and/or generate some other response upon the opening orclosing of the lid. Containers 20 can also utilize connectivity andcommunication technologies such as RFID technology to track the movementand usage of the container 20.

Such configurations may involve specific compartments within thecontainer 20 for hosting the ancillary/supplemental component. In someembodiments, a multiple body wall structure could include a cap withinthe wall to contain the particular component. In other embodiment, aspecific compartment is shaped in the applicable location within thecontainer 20 for use of the ancillary/supplemental component.

M. Prior Art Constraints

The prior art appears to affirmatively teach away from the innovativeattributes of the container 20. Many applications of containertechnology exhibit relatively few changes in recent years. For example,the common disposable cups of 2011 are not all that different from thedisposable cups that were manufactured in 2001, 1991, 1981, or evenearlier. There are significant reasons for the lack of innovation inmany areas of container design such as disposable cups. Disposable cupsare extremely high volume commodities that are subject to significantcost constraints and relatively high functional reliabilityrequirements. When cost constraints and reliability requirements arecoupled with intrinsic manufacturing limitations, it is easy to see whythe conventional disposable cup has not changed much over the years. Forexample, to the extent that some individuals may have sought to design apaper cup with an attached lid not comprised of plastic, such designswere at best too expensive to manufacture or insufficiently reliable forconsumer use. At worst, such approaches could actually be impossible tomass produce effectively.

The unfortunate interactions of economic, reliability, and manufacturingconstraints have in many respects hampered innovation in disposablecontainer technology. For example, the curved hinge 56 illustrated inFIGS. 2 d, 6 b, 6 c, 7 a, 7 d, and 9 b is believed to be actively taughtaway from by the prior art. Similarly, attributes such as the horizontalventing through ventilation gaps 29, a debossed cover 27, curved sidescore lines 55, the use of a plate 24, the use of a plate 24 inconjunction with flaps 54 and/or a reinforcement member 23 appear to runcounter to the teachings of the prior art.

The prior art approach to many structural and insulation issues is toadd thickness to the container 20, an approach which is directlycontrary to the flexibility required to mass produce a container 20 withan integral lid 28 made of a paperboard or similar material.

The prior art teaches away from the container 20 in part because of costconstraints, functionality requirements, manufacturing constraints, etc.have collectively left those of ordinary skill in the prior art into anintellectual dead end with respect to the design of containers,particularly in the context of disposable containers.

N. Alternative Embodiments

In accordance with the provisions of the patent statutes, the principlesand modes of operation of the container have been explained andillustrated in a variety of embodiments and configurations. However, itmust be understood that this inventive container 20 may be practicedotherwise than is specifically explained and illustrated withoutdeparting from its spirit or scope.

Similarly the methods of using containers and the methods ofmanufacturing containers should also be interpreted broadly.

III. INTRODUCTION OF ELEMENTS

FIG. 2 a is a diagram illustrating an example of an elevated rear viewof a container 20 in a fully closed state.

The container 20 illustrated in FIG. 2 a is a cup that can be machinedfrom and/or into a single piece of paper, paperboard, or similarmaterial. Different ways to manufacture the container 20 are describedin detail below.

Different embodiments of the container 20 can involve different types ofproducts, different material compositions, and different manufacturingprocesses. Each embodiment of the container 20 will include a containerbody (the “body”) 22 and a lid 28. Some containers 20 can include morethan one body 22 and/or more than one lid 28. The body 22 and lid 28 canbe implemented in a wide variety of different shapes and sizes usingdifferent materials and coatings. The container 20 will also include abody hinge 56. All other components in the various Figures are optionaland need not be included in all embodiments of the container 20.

Most embodiments of the container 20 will include a plate 24 that isconnected to both the lid 28 and to the body 22, with one end of theplate 24 being connected to the lid 28 and the other end of the platebeing connected to the body 22. Embodiments that include a plate 24 willtypically include a plate hinge 26 and flaps 54, although the presenceof flaps 54 does not necessitate the presence of the plate 24.

In some embodiments, the lid 28 and even the plate 24 can be configuredto be removable from the container 20, such as through perforated edgesto a paperboard or other material that can be removed by hand. In otherembodiments, the body 22, lid 28, and plate 24 are integral to eachother and are not configured to be intentionally separable from eachother.

A. Body

The body 22 of the container 20 typically constitutes the majority ofthe surface area of the container 22. The body 22 of the container 20also typically defines the shape, size, and contours of the container20. For example, in FIG. 2 d, the container 20 is a cup that issubstantially cylindrical in shape. The shape of the container 20 inFIG. 2 d is the result of a substantially cylindrical body 22. The body22 of the container 20 may include various score lines for the purposesof reinforcing the structural strength and integrity of the container 20as well as functions such as sealing the lid 28 in a closed position. Asdiscussed both above and below, the shape of the container 20 can besignificantly less cylindrical when the container 20 is a fully closedposition. Various figures can be contrasted to visualize thisattributes. For example, the containers 20 a stack of containers 20illustrated in FIG. 9 b are in a fully open state and thus substantiallycylindrical in shape (which facilitates better stacking capabilities)while the overall shape of the containers 20 stacked in FIG. 9 a aresubstantially more elliptical in shape. The difference being that thecurved hinge 56 in the open position of FIGS. 9 b and 9 c issubstantially straight when the container 20 is the closed position ofFIG. 9 a.

In contrast to other components of the container 20, the body 22 isdesigned to be the least impacted by the transition of the container 20from one state to another. Many portions of the body 22 such as thebottom surface or base 40 of the body 22 are totally unaffected bytransitions in operating states. However, the portion of the bodyimmediately underneath the body hinge 56 can be significantly impactedby the transition of the container from a fully opened to a fully closedstate, or vice versa. FIG. 7 f (the body 22 when the container 22 is ina fully open state) and FIG. 7 g (the body 22 when the container 22 isin a fully closed state) are discussed below.

The bottom portion of the body 22 typically serves as the base 40 of thecontainer 20 with the lid 28 being placed in a vertical position that ishigher than most or even all of the body 22, depending on the particularembodiment of the container 22 and the particular operating state of thelid 28. In FIG. 2 a, the uppermost portion of a tab 30 (which can extendoff of and be part of the lid 28) represents the highest vertical pointon the container 20 in a conventional orientation of the container 20when the container 20 is in a fully closed operatingconfiguration/state. Conversely, the lowest vertical portion of thecontainer 20 illustrated in FIG. 2 a is a base surface 40 of the body 22upon which the container 20 sits when placed on a substantially flatsurface such as a table. The relative vertical directions of up anddown, as well as the perspective of relative horizontal attributesversus relative vertical attributes are discussed from the perspectiveof a container 20 supported by the base 40 on a substantially flatsurface.

In many embodiments of the container 20, the body 22 will be comprisedprimarily of paper or paperboard. Different embodiments of the container20 may require additional linings, additional material, or entirelydifferent material. For example, polyethylene can be used to reinforcecertain portions of the body 22 or can be used to comprise the entirebody 22. Moreover, in an aseptic embodiment of the container 20, thelist of materials for use in the body 22 can include but are not limitedto paperboard, aluminum foil, metalized film, ethylene acrylic acid,low-density polyethylene, liner low-density polyethylene, nylon,polypropylene, polystyrene, polyvinylidine chloride, and/or ethylenevinyl alcohol.

The body 22 of the container 20 can itself be broken down further intovarious components and elements. Some elements such as a cavity 46 areinherent to the concept of a container 20 while other elements such as acurled rim 34, a head wall 36 above the inner groove 52, and the platesupport score lines 38 are optional.

1. Cavity

A cavity 46 (which can also be referred to as a chamber 46) is the emptyspace within the body 22 of the container 20 that is used to store thecontents or product. For example, in the context of a coffee cupcontainer 20, the cavity 46 is the space within the body 22 that housesthe coffee.

The cavity 46 is illustrated in FIG. 6 a. Dotted lines are used toillustrate the contours of the cavity 46 because the wall 42 of the body22 blocks the cavity 46 from view. The cavity 46 includes a bottomboundary which can be referred to as an internal floor surface 39 (whichcan also be referred to a cavity bottom 39) and interior walls 44.

In many embodiments of the container 20, the cavity 46 will be shaped ina substantially identical manner to the outer appearance of the body 22.However, in alternative embodiments, different shapes and configurationscan be implemented, particularly if the container 20 requires structuralreinforcements to maintain the integrity of the body 22. In suchinstances, reinforcing structures may be placed within the body 22,altering its interior shape, i.e. the shape of the cavity 46. Differentshapes may also be utilized if some of the ancillary/supplementalcomponents discussed above are implemented for a particular embodimentof the container 20.

Some embodiments of the container 20 can include multiple cavities 46for separating two or more products within the container 20. Suchembodiments can include internal structures to mix the contents ifdesired, or to keep them permanently separate. For example a container20 could be configured to hold 2 different and separate drinks, with thecavity 46 being split into two separate holding areas. Other containers20 involving foodstuffs or contents having nothing to do with beveragesor food can also involve partitioned cavities 46.

2. Walls

The cavity 46 of the body 22 is shaped by the material surrounding thecavity 46 which can be referred to as a wall 42. In the context of acylindrically shaped or substantially cylindrically shaped cavity 46,the wall 42 will often be similarly shaped. Some embodiments of thecontainer 20 can involve single-layered wall architecture. Otherembodiments may involve a framework involving two, three or more layers.For example, in some embodiments, a three layered approach involving twolayers of material surrounding a layer of air can be used to comprisethe walls 42. Some attributes of the wall(s) 42 will be dependent uponmanufacturing concerns. For example, in shaping a substantiallycylindrical container 20 from a substantially flat blank or combinationof blanks, an adhesive can be used to secure the shape of the cup.Temperature, pressure, folding, embossing, debossing, and otherprocesses can also be used in shaping and securing the wall(s) 42. Suchprocesses will impact the attributes of the wall(s) 42.

In the context of containers 20 used for beverage or food products, thecontainer 20 can be manufactured such that no adhesive is used on aportion of an interior surface 44 of a wall 42. This prevents such anadhesive from coming into contact with the contents of the container 20,which can be desirable in terms of complying with Food and DrugAdministration (“FDA”) regulations.

In aseptic embodiments of the container 20, the walls 42 will not becomprised primarily of paperboard. If paperboard is used, it will beused in conjunction with substantial portions of other materials.

3. Rim

As illustrated in FIG. 2 a, a rim 34 (which can also be referred to as atop curl 34) can represent the highest vertical position of the body 22.The rim 34 is typically a reinforced exterior surface at the top of thebody 22. Some embodiments of the container 20 will not include a rim 34,but the rim 34 is often useful for strengthening and reinforcing thestructural integrity of the container 20. Rims 34 can also aid users inthe use of the container 20. For example, in the context of a cupcontainer 20 used to hold a beverage, the rim 34 can assist a drinker inavoiding a spill as well as making the coffee cup container morecomfortable to use. The rim 34 can also insulate the drinker from abeverage that is particular hot or particular cold. For example, a rim34 with a serrated edge may serve to cool a hot beverage as the userdrinks from the container 20. The rim 34 can also include a pinched endsecured with a pinch lock.

As illustrated in FIG. 2 a, the rim 34 can comprised in the shape of atube or a close geometric proximity to a full curl. In many embodimentsof the container 20, the rim 34 is substantially in the shape of ahollow cylinder. In some embodiments, the rim 34 may have the shape of apartial cylinder with less than 360 degrees of surface

In the illustration of FIG. 2 a, the rim 34 is on top of a portion 36 ofthe body 22 that is vertically higher than the lid 28 when the lid 28 isin a fully closed configuration/state (i.e. when the lid 28 is securedwithin an internal groove 52). The top portion 36 of the body 22 oftenincludes a variety of score lines, which can be vertical, horizontal, ora combination thereof. The portion 36 of the body 22 that is verticallyabove the internal groove 52 can also be referred to as the head-wall 36of the body 22. The rim 34 resides on top of the head-wall 36.

In some embodiments of the container 20, the rim 34 will cover theentire portion of the body 22 that is not covered by the plate 24 or aflap 54. In other embodiments of the container 20, coverage of the rim34 is not comprehensive, allowing in certain embodiments, the portion 36of the body 22 closest to the flaps 54 to be folded inwardly toreinforce the functionality provided by the flaps 54. To maximize theflexibility of the plate 24 and or flaps 54, it is often desirable forat least a couple of millimeters of the top portion 36 to not be coveredby the rim 34.

In many embodiments of the container 20 that involve a cylindrical orsubstantially cylindrical body 22, the rim 34 forms an arc 41 betweenapproximately 299 degrees and approximately 180 degrees. In alternativeembodiments, the arc 41 could reach approximately 270 degrees or formsignificantly less than a 180 degree semi-circle. In FIG. 6 b, the arc41 is approximately 270 degrees. In FIG. 6 c, the arc 4 l isapproximately 180 degrees. Any variation between those two values can beimplemented in various embodiments of the container 20. In manyembodiments, it is desirable for the arc 41 to be between about 200degrees and 240 degrees.

4. Head-Wall

The head-wall 36 (which can also be referred to as a headwall 36 or headwall 36) underneath the rim 34 can provide Insulation and a barrier forsafety, making the container 20 easier to use, particularly with respectto embodiments involving liquid beverages. The head-wall 36 is theportion of the body 22 that is below the rim 34 but above the loop 61formed by the body hinge 56 and inner groove 52.

5. Interior Surfaces Vs. Exterior Surfaces

In many embodiments of the container 20, there is a surface or otherelement that faces inwards towards the cavity 46 and a correspondingsurface or other element that faces outwards towards the environment ofthe container 20.

The walls 42 of the body 22 are made up of both exterior surfaces andinterior surfaces. An exterior surface is a surface of the wall 42/body22 that faces outward from the container 20. An interior surface 44 is asurface of the wall 42/body 22 that faces inward towards the body 22,typically the cavity 46 or in some embodiments, another interior surfacethat compartmentalizes the cavity 46. FIG. 6 a illustrates internalsurfaces. The other figures focus on external surfaces.

Similarly, the headwall 36 has an inward facing surface and outwardfacing surface. The score line represented by element 53 is the exteriorface of the inner groove 52, both of which are part of the loop 61 thatencircles the container 20.

In FIG. 2 a, one exterior surface 42 of the body 22 is the portion ofthe body 22 that is substantially cylindrical in shape that runs from abottom to the top of the body 22. A corresponding interior surface 44that is illustrated with a dotted line because it is not visible fromthe exterior of the container 20 is also cylindrical in shape and runsfrom a bottom to the top of the container 20.

The head-wall 36 of the body 22 that extends upwards from the closed lid28 includes both an exterior surface as well as an interior surface. Therim 34 rests on the vertical protrusion 36.

The bottom portion of the body 22 includes both interior surfaces 39(facing upwards towards the cavity 46) and exterior surfaces 40 (facingdownwards towards the surface on which the container 20 rests). Thebottommost exterior surface of the body 22 is referred to as a base 40.The bottommost interior surface of the body 22 (which can also bethought of as the bottommost exterior “surface” of the cavity 46) isreferred to as a floor 39. The floor 39 of the cavity is illustratedwith a dotted line in FIG. 6 a because the cavity 46 is not visible fromthe outside of the container 20. A wide variety of different designs canbe incorporated into the base 40 of the container 20. The shape of thecontainer 20 will typically impact the desirable shape and configurationof the base 40.

6. Score Lines

A score line is a fold or crease in the material of the container 20.Score lines can be implemented through the application of pressure,heat, or combinations of both. As illustrated in FIG. 2 a, the body 22of the container 20 can include a variety of different score lines toreinforce the strength of the body 22 or for other purposes. Other partsof the container 20 such as the plate 24, the flaps 54, or the lid 28can also include score lines for structural reinforcement purposes aswell as for the purpose of facilitating the movement of the lid 28between open and closed operating states.

In the context of the body 22, the purpose of a score line is typicallyto constrain movement or deformation. Score lines can be orientedvertically (see element 38) or horizontally (see element 56). Differentembodiments of the container 20 can include fewer score lines or morescore lines than the illustration in FIG. 2 a.

Score lines can fully encircle a cross section of the container 20 or beonly partial in scope. For example, a substantially horizontal scoreline 61 (which can also be referred to as a “loop” 61) could run acrossthe entire circumference of a cylindrical body 22. In contrast, apartial horizontal score line may be limited to running under onlythrough the portions of the body 22 that are directly under the plate24, the plate 24 and flaps 54, the rim 34, or some other component orelement. A horizontal score line 56 separating the body 22 from theplate 24 and flaps 54 can also be referred to a body hinge 56. It isoften helpful to include horizontal score lines on the body 22 of thecontainer 20 that are parallel to the score line serving as body hinge56 between the plate 24 and the body 22 because the connector 56 betweenthe plate 24 and the body 22 is often important in supporting theability of the plate 24 to support the movement of the lid 28.

Vertical score lines can similarly be full (running from top to bottom)or merely partial. As illustrated in FIG. 1 a, vertical score lines 38(which can also be referred to as “plate support score lines” 38) in thebody 22 can extend upwards to the plate 38 to reinforce the structuralintegrity of the plate 24 and the ability of the plate 24 to assist insecuring the lid 28 in a closed position. Some embodiments of thecontainer 20 may include full vertical score lines spaced evenlythroughout portion of the body 22 covered by the rim 34. For example,vertical score lines could be placed below the rim 34 every “X” numberof millimeters to enhance the structural strength of the container 20.Horizontal score lines could also be distributed throughout the body 22to reinforce the structure of the body. However, one particularhorizontal score line 61 is particularly important. As illustrated inFIGS. 7 a and 7 b, the primary score line 61 can comprise the body hinge56 and the inner groove 52. The body hinge 56 can have a significantimpact on the functionality of the container 20 as well as the shape ofthe container 20.

With the exception of the body hinge 56 (and the flap bottom score lines57 if present), the score lines 70 on the body 22 of the container arenon-foldable score lines 72.

a. Body Hinge

The horizontal score line 61 can include the body hinge 56 or in otherwords, the body hinge 56 can be part of a greater horizontal score line61. The body hinge 56 can divide the body 22 of the container 20 fromthe plate 24 and flaps 54 of the container 20. The body hinge 56 it isattached to the body 22 of the container 20 and it serves as a hinge tofacilitate the opening and closing of the lid 28. The body hinge 56 isone of the components that is illustrated in FIGS. 1 a, 1 b, and 1 c.

The body hinge 56 works in conjunction with the plate hinge 26 tofacilitate the opening and closing of the lid 28. The body hinge 56 andthe inner groove score line 52 can fully encircle a cross-section of thecontainer 20 or in other embodiments, substantially encircle across-section of the container 20.

As discussed below, the inner groove score line 52 is typically circularin shape or substantially circular in shape in the context of acontainer 20 that is substantially cylindrical in shape. As illustratedin FIG. 7 b, the shape of the body hinge 56 can be in the shape of asubstantially straight line segment connecting to a substantially curvedinner groove score line 52. As is illustrated in FIG. 7 c, the shape ofthe body hinge 56 can be that of a substantially curved/circular arcconnecting a substantially curved/circular inner grove score line 52. Inmany embodiments of the container 20, the body hinge 56 is substantiallycurved in shape (with a substantially circular loop 61) when thecontainer 20 is in a fully open position and substantially straight inshape when the container 20 is in a fully closed position. In otherembodiments, even an open state of the container 20 will involve a bodyhinge 56 that is substantially less circular.

The shape of the body hinge 56 will often depend on the manufacturingprocess. If the body hinge 56 is machined into the blank prior to thefusing of the blanks together, the body hinge 56 will be substantiallymore straight than it otherwise would be. If in contrast, the primaryscore line 61 is machined after the blanks have been fused together andshaped, the body hinge 56 can be substantially circular when thecontainer 20 is in a fully open state.

In many embodiments, the body hinge 56 is a score line. However, inalternative embodiments of the container 20, different types ofprocessing (i.e. not necessary score lines) can be implemented into thecontainer 20 to provide for the functionality of the body hinge 56 orother types of hinges.

b. Inner Groove Score Line

Some embodiments of the container 20 can include horizontal score line52 (the “inner groove score line” 52) that connects with the body hinge56 to form a score line 61 that substantially circles or even fullyencircles an outer surface cross section of the container 20. See FIGS.7 a and 7 b.

The interior facing surface of the inner groove 52 can be used to helpseal with lid in a closed position. This can be true in both aseptic andnon-aseptic embodiments of the container 20. However, aseptic containers20 with the aid of the flange 59 have less need of the inner groove 52.The exterior facing surface of the inner groove 52 serves to sustain thestructural integrity of the container 20.

The cavity of the inner grove score line 52 can be referred to as theinner groove 52 or the lid channel seat groove 52. FIG. 8 c provides anexample of the inner groove 52 serving to secure the lid 28 in a closedand sealed state. FIGS. 8 d and 8 e illustrate examples of an innergrove 52. In many embodiments of the container 20, an inner groove angle64 of about 30 degrees is highly desirable. In alternative embodiments,the inner groove angle 64 can range as low as about 20 degrees and ashigh as about 60 degrees. In many embodiments of the container 20, theinner groove 52 will have a cross section that is substantially convexin shape.

In many embodiments, the inner groove 52 is formed as a score line.However, in alternative embodiments of the container 20, different typesof processing (i.e. not necessarily score lines) can be implemented intothe container 20 to provide for the functionality of a groove 52 thatserves as a mechanism for securing the lid 28. For example a flange 59could be used instead of the inner groove 52 or in addition to an innergroove 52.

c. Chevrons

A chevron can be embossed or debossed into any portion of the container20, including the body 22, the plate 24, or the lid 28. Chevrons serveto structurally reinforce the applicable portion of the container 20. Nochevrons are illustrated in the body 22 of the container 20 in FIGS. 2a-2 d. FIG. 6 g illustrates chevrons 59 on the lid 28. Similar chevrons59 can be placed elsewhere on the container 20 including the body 22 orthe plate 24 to facilitate the structural integrity of the container 20.

d. Dimples/Dimple Groups

In order to facilitate better thermal insulation, make the container 20easier to grip, or just to alter the way users experience the container20, the body 20 of the container 20 can include a variety of dimples 31or even dimple groups.

FIG. 11 a is diagram illustrating an example of a sidewall blank 106that includes two groupings 33 of dimples 31. The dimple groups 33 arepositioned on the wall 42 of the body to facilitate grip and heatinsulation. The number, shape, size, and position of dimples 31 can varywidely from embodiment to embodiment of the container 20. Somecontainers 20 will not include any dimples 31. Some embodiments of thecontainer 20 may be used in conjunction with sleeves that have dimples31 in lieu of the wall 42 itself having dimples 31.

FIG. 11 b is a diagram illustrating an example of a container 20 with abody wall 42 substantially covered in dimples 31. Although there is noinherent limit to the number and usage of dimples 31 there is littlereason in most instances to go beyond the boundary of the body 22 wall42 in the placement of dimples 31.

In many instances, dimples 31 will protrude to the exterior of thecontainer 20. However, dimples 31 can be implemented to protrude inwardsto the cavity 46 or in both interior and exterior directions. FIG. 11 cis cross section diagram of a body wall 42 with dimples 31 protrudingoutward from the container 20. FIG. 11 d is a cross section diagram of abody wall with dimples protruding inward towards the cavity of thecontainer. FIG. 11 e is a cross section diagram of a body wall withdimples protruding both inwards towards the cavity of the container andoutward towards the external environment of the container.

Dimples 31 can be implemented in a variety of different shapes, sizes,and configurations. In addition to heat insulation functionality,dimples 31 can also enhance the user experience in handling thecontainer 20. Dimples 31 impact the look of the container 20, as well asthe resulting sense of touch that a user experiences while in contactwith the dimples 31 on the container 20.

7. Bottom Portion

The bottom 40 surface of the body 22 serves as the bottom of thecontainer 20. There are a wide variety of different bottoms 40 that canbe incorporated into the container 20. In some instances, the contentsof container 20 will impact the structure of the bottom 40. The bottom40 can be curled (see FIG. 10 f) as well as finished, knurled, andsquared (see FIG. 10 g).

B. Plate

A plate 24 is a surface area of the container 20 that is configured tosupport the movement of the lid 28. The plate 24 acts as an interfacebetween a lid 28 that must move in order for the container 20 to beopened or closed and a body 22 that involves far less movement.

Just as the body 22 can have exterior surfaces facing in an outwarddirection and interior surfaces facing in an inward direction, the plate24 can include both an outward surface and an inward surface. Similarly,the plate 24 can also include both vertical and horizontal score lineswith the boundaries of the plate 24 being typically marked by scorelines. A plate 24 can include side score lines 55 and horizontal scorelines 56 and 26.

The plate 24 and two flaps 54 that are illustrated in FIG. 2 afacilitate the ability of users to open and close the lid 28 whilefacilitating the strength and tightness of the container 20. If the lid28 cannot be secured in a closed position, then the ability to utilizethe container 20 is compromised because an unfastened lid 28 can resultin the unintended change of an operating configuration/state from closedto open. For example, in the context of a beverage container 20, acontainer 20 that cannot be closed and sealed in a watertight manner isof only limited use.

Embodiments of the container 20 that include a plate 24 allow for thelid 28 to be open or closed without altering the structure of the lid28. By leaving the structure of lid 28 unchanged, the structuralintegrity of the lid 28 and the ability of a closed lid 28 to seal thecontents of the cavity 46 are enhanced. The motion of the lid 28 isfacilitated by the plate 24 or the plate 24 in conjunction with theflaps 54. A variety of score lines are typically used to delineate theboundaries of the plate 24 and flaps 54.

Just as the body 22 can be comprised of a wide range of differentmaterials or combinations of those materials, so can the plate 24 besimilarly comprised. In some embodiments, differences in materialscomposition, thickness, and/or other factors relative to the plate 24and the body 22 can be used to enhance the functionality of the plate 24in facilitating the movement of the lid 28 into open and closedpositions.

As discussed above, different embodiments of the container 20 canutilize different types of score lines at different locations withdifferent attributes

1. Body Hinge

The body hinge 56 connects the plate 24 to the body 22. The body hinge56 is discussed above. The body hinge 56 in many embodiments of thecontainer 20 represents the lowest part of the container 20 that isdesigned to move with the opening or closing of the lid 28. As discussedabove and below and as is illustrated by contrasting FIG. 7 f with FIG.7 g or FIG. 7 c with FIG. 7 d, the movement of the body hinge 56involves moving the portion of the body 22 beneath the body hinge 56.

2. Plate Hinge

Returning to FIG. 2 a, a plate hinge 26 connects the plate 24 to the lid28. The plate hinge 26 is a score line that traverses all orsubstantially all of the boundary between the plate 24 and the lid 28.It may also divide portions of the flaps 54 (if any) that may be incontact with the lid 28.

The plate hinge 26 and the body hinge 56 can function in conjunctionwith each other as a dual hinged closing/opening mechanism for thecontainer 20. Examples of plate hinges 26 are illustrated in FIGS. 1 a,1 c, 2 a-2 d, and 6 d. FIG. 6 e illustrates an example of a plate hinge26 that includes a hinge break 45.

3. Side Score Lines

Two side score lines 55 serve to connect the plate 24 from two exteriorflaps 54 in embodiments of the container 20 that include the two flaps54. As illustrated in FIGS. 5 c and 5 d, the side score lines 55 can becurved. Curved side score lines 55 can form a substantially circular arc41 along with the lid 28. The curved shape of the side score lines 55can enhance a larger circular arc 41 and preserve a more circular orelliptical shape of the container 20 (if the container 20 issubstantially circular or elliptical in shape in the first place) whenthe container 20 is in a closed position.

4. Flaps

Many embodiments of the container 20 will include two flaps 54, one toeach side of the plate 24, to facilitate the sealing of the container 20in a closed position. The flaps 54 can also assist users in moving thecontainer 20 from one operating state to another. The flaps 54 can alsoserve to ventilate the cavity 46 of the container 20.

A flap 54 is a surface horizontally adjacent to the plate 24, butseparated from the plate 24 by a side score line 55. The boundaries ofthe flaps 54 are often demarcated by substantially vertical 55 andsubstantially horizontal score lines 57. As discussed above, one or moreflaps 54 may be used to support and enhance the ability of the plate 24to function as a hinge for the lid 28. Some embodiments of the flaps 54can be configured to be further twisted or pushed in by the user tofurther secure the lid 28 in a closed position. Such twisting or pushingin may render the container 20 undesirable for subsequent opening andrefilling.

An embodiment of the container 20 that uses a plate 24 need not includeany flaps 54, but a combination of one plate 24 with one flap 54 on eachside is often desirable. Some embodiments of aseptic containers 20 (seeFIGS. 1 b and 6 j) will include flaps 54 but no plate 24.

As illustrated in FIG. 5 d, a flap angle 97 (the angle formed by theside score line 55 and a bottom score line 57) is often between about 35degrees and about 70 degrees.

5. Flap Bottom Score Lines

Some embodiments of the container 20 will include a flap bottom scoreline 57 that connects the bottom portion of the flap 54 to a portion ofthe body 22 that is vertically higher than the body hinge 56 and theinner groove score line 52.

In some embodiments of the container 20, the bottom flap score line 57,the body hinge 56, and the inner grove score line 52 intersect with eachother as illustrated in FIG. 2 a. In other embodiments, either the flapbottom score line 57 or the side score lines 55 will not be long enoughto intersect.

6. Skid Locks

Some embodiments of the plate 24 can include one or more skid locks 58to facilitate the ability of users to stack the containers 20 on top ofeach other even if the lids 28 are closed. Skid locks 58 in conjunctionwith the rim 34 serve to constrain the lower portion of the container 20allowing the containers 20 to be vertically stacked onto each other evenwhen the lids 28 are closed. Skid locks 58 can be implemented into theplate 24 using a wide variety of different manufacturing processes.

The ability of skid locks 58 to facilitate the stacking of closedcontainers 20 is illustrated in FIG. 9 a.

7. Hinge Break

As illustrated in FIGS. 6 f and 6 i, some embodiments of the plate 24may include a hinge break 45. The hinge break 45 can facilitate thetransition functionality of the plate hinge 26. The hinge break 45 canalso provide an opening in which the tab 30 can be pressed into when thetab 30 is in a fully opened position. For example, instead of the tab 30point upwards in FIG. 2 b, the tab 30 could be pushed into the openingresulting from the hinge break 45. It can provide a way to secure thetab 30 in a position that will prevent the tab 30 from interfering withthe use of the container 20 while the container 20 is being used. Forexample, in an embodiment of the container 20 used for the purposes ofstoring and drinking beverages, the tab 30 can be secured in the hingebreak 45 when the user is drinking from the container 20.

In FIGS. 6 f and 6 i, the hinge break 45 is a semi-circle cut out fromthe plate hinge 26. Many embodiments of the plate 24 will includedifferently shaped hinge breaks 45, differently positioned hinge breaks45, or no hinge break 45 whatsoever.

8. Reinforcement Member

Some embodiments of the container 20 that include a plate 24 may alsoinclude a reinforcement member 23 underneath the plate 24 that connectsthe lid 28 to the plate 24 and assists in the opening and closing of thelid 28. As illustrated in FIGS. 5 c and 5 d, the reinforcement member 23can be part of the lid blank 104 that is mated, fixed, or fastened tothe interior surface of plate 24 on the sidewall blank 106.

9. Ventilation Gaps

Some embodiments of the container that include a reinforcement member 23may also include one or more ventilation gaps 29. Such gaps 29facilitate the ventilation of the container 20. Ventilation of thecontainer 20 can be particularly important in the context of containers20 used to hold beverages. The ventilation provided by the ventilationgaps 29 is in a horizontal direction when the lid 28 of the container 20is closed.

10. Additional Score Lines and Chevrons

As discussed above, the purpose of the plate 24 is to insulate the body22 from the magnitude of movement required to open and close the lid 28.A variety of additional score lines and/or chevrons can be used tofurther support the underlying functionality of the plate 24 and theflaps 54. Score lines, vertical creases, and chevrons can also be usedto facilitate the ability of users to properly seal the lid 28 in aclosed position by making it easier for users of the container 20 toproperly manipulate the container 20.

The plate 24 and its subsidiary components act to insulate the body 22of the container 20 relative to the significant motion by the lid 28while at the same time facilitating the ability of the lid 28 to move ina manner that is required to open, close, and seal the container 20. Theplate 24 also serves to make the opening, closing, and sealing of thelid as easy as possible for users to achieve while providing users withthe features of reliability and reusability. Different embodiments ofbody hinges 56, lid hinges 26, flaps 54, and other plate 24 subsidiarycomponents can be incorporated into the container 20.

11. Insulation Layer

Some embodiments of the container 20 can include an insulation layer 77beneath the plate 24 and/or lid 28 (illustrated in FIG. 6 k with dottedlines because the layer 77 is underneath the top surfaces of the lid 28and plate 24). The primary purpose of the insulation layer 77 is toinsulate the material in the lid 28 from potential heat associated withthe contents in the cavity 46 of the container 20. However, theinsulation layer 77 can also help shape and structurally reinforce thelid 28 as it is opened and closed. The insulation layer 77 can becomprised of a variety of different materials, including but not limitedto a heat laminated foam that is formed from a high densitypolyethylene, low density polyethylene, linear low density polyethylene,and/or oriented polypropylene.

C. Lid

A lid 28 is the means by which a container 20 is closed and in somecases, sealed (such as the case with watertight or substantiallywatertight containers). In some embodiments, a grove 52 in the body 22helps secure the lid 28 when it is moved to a closed/sealed position. Inother embodiments, a flange 59 is used. In some embodiments, both aflange 59 and an inner groove 52 shaped for the purposes of sealing thelid 28 are used.

Although the position of the lid 28 determines whether the container 20is in a closed state/configuration or an open state/configuration, thechange in the position of the lid 32 is not achieved through anystructure change to the lid 32. To the contrary, it is the plate 24(sometimes in conjunction with the flaps 54) that serve as the hingeupon which the lid 28 can be moved. In the example of FIG. 2 a, the lid28 moves by being rotated around the plate hinge 26 and the body hinge56.

In many embodiments of the container 20, the lid 28 is substantiallycircular in shape and need not be very thick. In many embodiments of thecontainer 20, the lid 28 is substantially parallel to the surface onwhich the container 20 rests when the lid is in a closed operatingconfiguration/state. For example, in a typical beverage cup embodimentof the container 20, the lid 28 is a closed position in substantiallyparallel to the to the ground surface on which the base 40 of thecontainer 20 can rest.

The lid 28 can be in an open position, a closed position, or in someinstances, a partially open/partially closed position. In manyembodiments of the container 20, the lid 28 is integral to the plate 24,and the plate 24 is integral to the body 22. The lid 28 can be comprisedof the same material as the plate 24 and body 22. Examples of lids 28illustrated in FIGS. 1 a-1 c, 2 a-2 d, 6 g-6 j, and 7 e. FIG. 5 c alsoillustrates examples of lid-related attributes such as tabs 30 that arenot covers 27, covers 27 that are not tabs 30, openings 32, verticalcreases 25, debossed covers 27, and a connection to a reinforcementmember 23 to assist in the opening and closing of the lid 28.

In some embodiments, the lid 28 is thicker than other portions of thecontainer. In other embodiments, the edge 51 of the lid 28 may bethicker than other portions of the lid 28. In still other embodiments,the thickness of the lid 28 is equal to the thickness of the walls 42 ofthe container 20.

The ability to machine to a separate lid blank 104 makes it easier toinclude a lid 28 that is thicker than other portions of the container20.

1. Edge

Different embodiments of the lid 28 can include a potentially widevariety of different subcomponents. However, one common function of thelid 28 is the ability to close the container 20 and secure contentswithin the container 20. One attribute of the lid 28 that can facilitatethe ability of the lid 28 to secure a closed position is the edge 51 ofthe lid 28. The edge 51 can also be referred to as a lid edge 51. Inmany cup embodiments of the container 20, the lid 28 is secured withinan inner groove 52 of the container 20. The geometric configuration ofthe edge 51 and the inner groove 52 can enhance the functionality of thelid 28. For example, in some embodiments, the edge 51 of the lid 28includes one of a wide variety of wave rule shapes. The geometry of theinner groove 52 can similarly be configured to enhance the functionalityof the lid 28. FIG. 8 d illustrates an example of a lid groove 52geometry that can be implemented in the container 20. In manyembodiments, the inner groove 52 will have a convex shape, and an angle64 of about 30 degrees. In different embodiments, different shapes anddifferent angles 64 can be incorporated into the inner groove 52.

In many embodiments of the container 20, it may be useful to treat theedge 51 of the lid 28 with a material stronger than the materialcomprising the lid 28 generally or even the container 20 generally. Forexample, in the example of a cup comprised primarily of paperboard, itmay be desirable to treat the edge 51 with polyethylene. In otherembodiments, the entire lid 28 could be treated with polyethylene orsome other material.

2. Tab

Some embodiments of the lid 28 can include a tab 30 which serves as ahandle for opening and closing the lid 28. Different embodiments of thetab 30 can include a different number of score lines. In manyembodiments, the number of score lines in the tab 30 will depend onwhether the tab 30 is used to seal an opening 32 (see FIG. 2 b) in thelid 28. As illustrated in FIG. 2 a, the tab 30 includes a score line 48at the base of the tab 30 as well as a score line at the segment 50 ofthe tab 30 that transitions from a primarily horizontal orientation to aprimarily vertical orientation. This allows the tab 30 to facilitate thesealing and closing of the opening 32 (which can also be referred to asan opening 32) as well as the opening and closing of the lid 28. In manybeverage embodiments of the container 20, an additional third tab scoreline 60 (see FIG. 7 e) can be used to facilitate the ability of the userto push the tab 30 down into the opening 32 (also referred to as apassageway 32) so that the tab 30 does not interfere with the comfort ofthe user in drinking the beverage in the container 20. In otherembodiments, the tab 30 can be secured in the hinge break 45.

Returning to FIG. 2 a, the tab 30 is fastened to the lid 28 at a tabbase 48. The location of the tab base 48 can depend on whether or notthe lid 28 includes an opening 32. If the lid 28 does include an opening32, then the tab base 48 is typically the innermost edge of the opening32. If the lid 28 does not include an opening 32, then the tab base 48is typically located close to the outermost edge of the top surface ofthe lid 28.

The container 20 illustrated in FIG. 2 a includes both a tab 30 and anopening 32. The shape of the tab 30 can vary widely, but the tip of thetab 30 should serve to facilitate movement by the user and the shape ofthe lower portion of the tab 30 will typically depend on the shape ofthe opening 32.

The tab 30 can be located in a wide variety of different locations onthe lid 28. In FIG. 5 c, the tab 30 is positioned closed to the edge 51of the lid, midway between the opening 32 and the plate hinge 26. Inmany embodiments, the tab 30 will be oriented approximately 90 degreesdifferently than the illustration in FIG. 5 c, to allow the tab 30 tosit flush unto the lid 28 when containers 20 are nested together.

3. Opening/Passageway

Some embodiment of the lid 28 will include a passageway 32 toselectively expose the contents of the container 20. The passageway 32can also be referred to as an opening 32 or a movable lid partition 32.The passageway 32 can be open, closed, and sealed without otherwisemoving the lid 28. For example, in the context of a beverage container,the passageway 32 can allow the user to drink the contents of thecontainer 20 (through use of a straw or by simply tipping the containerin close proximity to an open mouth) while the lid 28 remains in aclosed position. The passageway 32 can be closed/sealed using the tab30. The passageway 32 in FIG. 2 a is illustrated with a dotted linebecause the passageway 32 is not visible. The passageway 32 in FIG. 2 ais filled up and sealed by the tab 30. The bottom portion of the tab 30in FIG. 2 a from the tab base 48 to the fold 50 is substantiallyparallel to the bottom surface of the container 20 and the top portionof the tab 30 from the fold 50 upwards protrudes straight upwards in theair where it can be most easily grasped.

The shape of the opening 32 and of the portion of the tab 30 used toplug the passageway 32, can vary widely from embodiment to embodiment.Some embodiments of the container 20 can include more than onepassageway 32. For example, some embodiments of a beverage container 20could include two or more openings 32 for the insertion of straws.

Additional illustrations of the movement of the tab 30 and the opening32 covered by the tab 30, can be seen in FIG. 2 b and FIG. 7 e.

FIG. 5 c shows a debossed cover 27 over an opening 32. The configurationillustrated in FIG. 5 c may be particularly desirable in the context ofcontainers 20 used in conjunction with warm beverages, such as hotchocolate, tea, coffee, etc.

In some embodiments of the container 20, a peel-off metallic sticker canbe used as a cover 27 the opening 32. Some embodiments of the container20 will not involve use of a cover 27, and instead the geometry of thecontainer 20 in conjunction with the fill height will eliminate the needfor a cover 27.

4. Chevrons

As illustrated in FIG. 6 g, the lid 28 can also include chevrons 49.Chevrons 49 in the lid can serve a variety of purposes that relate toassisting users in closing and opening the lid 28. For example, asillustrated in FIG. 6 g, chevrons 49 can assist users in centering theapplication of force to the lid 28 in closing the lid 28. Chevrons 49can also serve to increase the stiffness of the lid 28 as it is beingpushed or pulled by a user. The lid 28 of the container 20 can becomprised of a wide variety of different materials or combinations ofmaterials, as discussed with regards to the body 22 and the plate 24.

5. Lid Stiffener Score Lines

As illustrated in FIG. 6 h, one or more lid stiffener score lines 63 canbe used to reinforce the lid 28 immediately to the interior of the edge51. This can assist the sealing process, and make the lid 28 moredurable (i.e. properly function after many openings and closings).

6. Hinge Break

FIG. 6 i is the mirror image of FIG. 6 f, with the hinge break being inthe form a semi circle. As discussed above, the hinge break 45 is anoptional component but it can perform a variety of functions.

7. Vertical Creases

FIG. 5 c illustrates an example of vertical creases 25 in the lid 28that serve the structurally strengthen the lid 28, particularly throughthe process of being opened or closed.

8. Insulation Layer

As discussed above with respect to the plate 24, an insulation layer 77can also be positioned on the bottom of the lid 28 to insulate andstrengthen the lid 28.

D. Additional Elements/Components

Different embodiments of the container 20 can include a wide variety ofadditional elements/components. As discussed above, different score lineconfigurations can be incorporated into the container 20. In someembodiments, a tear back adhesive can be place on the lid 28 tofacilitate the pulling open of the lid 28. The structure and shape ofthe lid channel seat groove 52 can be modified to provide extrareinforcement analogous to that of a girdle. For example, additionalstructural components could be added to prevent the lid 28 from movingbeyond a particular closed position. Components such as chevrons 49 canbe placed at various locations of the container 20 to enhance structuralstrength at those locations. As illustrated in FIGS. 1 b and 6 j, thelid 28 may not always be attached to a plate 24 or a plate hinge 26, butcomponents such as a flange 59 can be added to assist the functionalityof sealing the container 20.

In some embodiments, an additional vertical body seam running up fromthe bottom of the body 22 to the outermost portion of the lid 28 and thelocation of the tab 30 could be used to further strengthen the container20. In some embodiments, the vertical body seam can include a lateraltab to facilitate the opening and closing of the container 20.

For embodiments involving the storage of food, the flaps 54 can includea cold seal adhesive that is water based. Pressure from the fingers ofthe users can then form a bond that will enhance the ability of thecontainer 20 to satisfy specification 276.170 FDA compliance as itpertains to direct food contact with respect to aqueous and fatty foods.

IV. OPERATING CONFIGURATIONS/STATES/POSITIONS

Depending on the product that a container 20 is designed to secure, thecontainer 20 can be configured in a variety of different states orpositions. For example, in the context of a beverage container 20, thecontainer 20 can be in a fully closed and sealed position to minimizethe ability of the beverage to escape from the container. An example ofthe fully closed and sealed configuration is illustrated in FIG. 2 a,where the lid 28 is closed and the opening 32 is also sealed by the tab30 which can include a variety of score lines designed to facilitate theability of the tab 30 to fill the opening 32.

FIG. 2 b illustrates an example of a lid 28 that is fully closed, but anopening 32 that is not blocked by the tab 30, permitting the beverage tobe consumed, but otherwise limiting the ability of the beverage to bespilled. As illustrated in the Figure, the tab 30 is straightened outinto a vertical or substantially vertical position as the opening 32 isunsealed. As discussed below with respect to FIG. 7 e, some embodimentsof the tab 30 will include an additional score line 60 designed tofacilitate the pushing of the tab 30 into the opening 32 so that the tab30 does not interfere with the drinking of the beverage through theopening 32. In other embodiments, a hinge break 45 is used to secure thetab 30. The transition from FIG. 2 a to FIG. 2 b can occur solely withthe movement of the tab 30.

FIG. 2 c illustrates an example of a lid 28 that is partially open.Although the position of the plate 24 in FIG. 2 c is identical to theposition of the plate 28 in FIG. 2 b and FIG. 2 a because the plate 24is fixed, the lid 28 is nonetheless not in a closed position. In manycontexts, the filling or refilling of the beverage container 20 isperformed while the container 20 is in the configuration of FIG. 2 c. Insome contexts, a user may drink from the container 20 while in the stateillustrated in FIG. 2 c. The transition from FIG. 2 b to FIG. 2 cinvolves movement of the lid 28 but not the movement of the plate 24.

FIG. 2 d illustrates an example of a container 20 in a state of maximumopenness. The illustrated configuration can be highly desirable for thepurposes of stacking empty containers 20 on top of each other. Theillustrated configuration can also be desirable in the filling orrefilling of the container 20, and in some instances, such as trying toclear out a cup of the remaining portions of a milk shake, for consumingthe contents of the container 20. The transition from FIG. 2 c to FIG. 2d involves primarily the moving of the plate 24 from its substantiallyhorizontal position to its substantially vertical position.

FIGS. 8 a, 8 b, and 8 c also illustrate different operating states fromdifferent points of view.

Different embodiments of the container 20 can include a wide variety ofdifferent positions, states, and operating configurations.

V. SHAPE CHANGE

As discussed above, the transition from one operating state to anotheroperating state can impact the shape of the container 20 by impactingthe shape of the body 22 underneath the body hinge 56. When the bodyhinge 56 is moved forward to transition the container away from a fullyopened state towards a fully closed state, the shape of the body 22 ofthe container in the aggregate is impacted. The magnitude and nature ofthe shape change can be impacted by the geometry and configuration ofthe components used in the particular embodiment of the container 20.The use of components such as an insulation layer 77, the reinforcementmember 23, and a variety of non-foldable score lines 72 can impede themagnitude of shape changes to the body 22 of the container 20 in theopening and closing of the container 20.

FIG. 7 a is a geometric diagram illustrating an example of asubstantially circular primary score line 61 comprised of asubstantially circular inner groove 52 and a substantially circular bodyhinge 52. In many embodiments of the container 20, this is the shape ofthe body 22 when the container 20 is in a fully open position. The shapeis also illustrated in FIGS. 2 d (in contrast to FIG. 2 a), 7 c (incontrast to FIG. 7 d), 7 f (in contrast to 7 g), and 8 b and 9 c (incontrast to FIG. 9 a).

FIG. 7 b is a geometric diagram illustrating an example of asubstantially circular primary score line 61 comprised of asubstantially circular inner groove 52 and a substantially straight bodyhinge 56. In some embodiments where the primary score line 61 isinitially imprinted on a blank instead of being added on after the fusedblank is shaped around the bottom blank 102, even in an open state, theshape of container 20 will be directionally closer to FIG. 7 b. However,with respect to embodiments involving a primary score line 61 addedafter the fused blank is shaped, FIGS. 2 a, 7 d, 7 e, 7 g, and 9 aillustrate a container 20 that is substantially elliptical in shapebecause the plate hinge 56 is less curved than when in a fully openstate.

FIG. 7 c is a bottom plan view diagram illustrating an example of acontainer 20 with the primary score line 61 illustrated in FIG. 7 a whenthe container 20 is in a fully open state.

FIG. 7 d is a bottom plan view illustrating an example of a container 20with the primary score line 61 illustrated in FIG. 7 b in a fully closedstate.

In addition to the use of a curved body hinge 56, the use of curved sidescore lines 55 can also have a substantial impact on the geometry of thecontainer 20, particularly in conjunction with the use of areinforcement member 23 and a larger arc 41. As illustrated in FIG. 6 k,the curvature of the side score line 55 can match the curvature of thelid 28 allowing the top of the container 20 to form a continuous arc 79.

VI. STACKING

FIGS. 9 a, 9 b, and 9 c illustrate examples of how similar containers 20can be stacked.

FIG. 9 a discloses a stack 90 of closed containers 20. Skid locks 58 onthe plate 24 are used to facilitate the stacking of the containers 20.Different numbers, locations, and configurations of skid locks 58 can beused to facilitate the functionality of container 20 stacking.

FIG. 9 b discloses a stack 94 of open containers 20 in a perspectiveview from which the substantially circular shape of the containers 20 isclearly evidence. FIG. 9 c discloses a similar stack 94 from a differentview.

The ability to effectively stack containers 20 can have importantimplications for how the containers 20 are shaped. For example, thereason why the bottom 40 of a disposable coffee cup has a smallerdiameter than the lid 28 is because it is necessary to stack the cups.As discussed above, the timing in the manufacturing process by which theprimary score line 61 is machined into the container 20 can have asignificant impact on the shape of the container 20. It is moredifficult to stack cups when the primary score line 61 is notsubstantially circular in shape when the cups are in fully openoperating states.

VII. METHODS OF USING

FIG. 3 a discloses an example of a method for opening a container 20 andFIG. 3 b discloses a mirror image of FIG. 3 a for closing a container20. In both flow chart diagrams, the flexing of the plate 24 and flaps54 involves flexing the foldable score lines 71, such as the body hinge56, the plate hinge 26, the side score lines 55 and the flap bottomscore lines 57.

There are many different alternative embodiments for transitioning thecontainer 20 from a fully opened state and a fully closed state. Asdiscussed above, different embodiments have a different number of tabs30 located in different positions on the container. Chevrons 49 can beadded in certain places to encourage users to press down on certainservices rather than others. The geometries of the horizontal scorelines and the thickness. Different coatings can be applied to differentlocations on the exterior surface of the container 20 to encouragedifferent user activities for opening and closing the container 20.

Different containers 20 can involve different components and differentsteps for the opening and closing of the container 20.

VIII. ADDITIONAL VIEWS A. Top View

FIG. 7 e is a diagram illustrating an example of a top view of container20 that is in a closed and sealed state. In this example of thecontainer 20, the tab 30 includes three score lines (48, 60, and 50) tofacilitate the ability of a user to push the tab 30 down into theopening 32 (also referred to as a passageway 32) so that the tab 30 doesnot enter the users mouth or otherwise interfere with the consumption ofthe beverage. The illustration in FIG. 7 e also includes two skid locks58 to facilitate the stacking of closed containers 20 as illustrated inFIG. 9 a.

B. Bottom View

FIG. 7 c is a diagram illustrating an example of a bottom view of acontainer 20 with a substantially circular primary score line 61 whenthe container 20 is in an opened state. FIG. 4 d is a diagramillustrating another example of a bottom view of a container 20 in whichthe primary horizontal score line 61 is not substantially circular inshape because the container 20 is either in a closed position and/or thescore line 61 was machined into the applicable blank prior to theshaping of the applicable blank around the bottom blank 102. Both FIGS.7 c and 7 d show the base 40.

As illustrated in the Figures, different base 40 configurations can beincorporated into different embodiments of the container 20. The type ofmaterial used to comprise the container 20 and the type of contentsanticipated to be held in the container 20 can influence the appropriatedesign of the bottom of the container 20.

C. Side View

FIG. 8 a is a diagram illustrating an example of a side view of acontainer 20. The container 20 in FIG. 8 a is in a similar operatingstate/configuration as the container 20 in FIG. 2 d, but from adifferent perspective. In this position, the portions of the tab 30, lid28, and plate 28 that are most exterior to the container 20 form asubstantially vertical line segment extending upwards from the exteriorsurface 42 of the body 22.

Although the lid 28 is substantially flat when closed, the curvature ofthe container 20 does not appear substantially flat as a line segment ina side view of the container 20 when the lid 28 is in a full uprightposition. FIG. 5 a illustrates only a small portion of the body hinge56, but the impact of the curved body hinge 56 does manifest itself inthe fact that the lid 28 is not a simply a straight line as isillustrated in FIG. 8 b.

As illustrated in FIG. 8 b, as the lid 28 moves more closely to a closedposition, the side view of the lid 28 takes on a more two-dimensionalappearance. This occurs because the originally curved body hinge 56becomes more straight as the lid 28 and plate 24 move forward.

FIG. 8 c is a diagram illustrating an example of a side view of aninterior body surface that includes a lid channel seat groove 52 tosecure the lid 28 in a closed position. Different geometric shapes canbe incorporated into the groove 52. Additional structures can also beadded to preclude the lid 28 from moving beyond an optimal closedposition. FIG. 8 d illustrates a close up view of the inner groove 52,with FIG. 8 e illustrating an example of the inner groove angle 64,which in many embodiments is about 30 degrees. In other embodiments theangle 64 can range from as low as about 15 degrees to as high as about65 degrees.

D. Front View

FIG. 8 f is a diagram illustrating an example of a front view of acontainer 20 that is in a fully closed operating state.

E. Side Tab View

FIG. 8 g illustrates the different positions of the tab 30 as thecontainer 20 transitions from closed and sealed (FIG. 2 a), to closedand unsealed (FIG. 2 b), open lid/plate secure (FIG. 2 c), and fullyopen (FIG. 2 d).

IX. METHOD OF MAKING

As discussed above, the container 20 can be manufactured in a widevariety of different ways using a wide variety of different tools. Thematerials used to manufacture the container 20 will have a significantimpact on the manufacturing processes used with respect to theparticular container 20. In the context of the disposable containers 20,many embodiments of the container 20 will be comprised primarily of sometype of paper or paperboard. Various coatings and adhesives can be usedto secure and/or strengthen certain portions of the container 20. Forexample, the lid 28, the edge 51 of the lid 28, or other parts of adisposable container could be coated with polylactic acid (PLA) or someother type of material. Disposable embodiments of aseptic containers 20will necessarily include significant materials in substitution of or inaddition to paperboard-type material.

A. Blanks

As discussed above with respect to FIGS. 4 a-4 b and FIGS. 5 a-5 d,containers 20 can be manufactured through the assembly of blanks. Blankscomprise flat pieces of material capable of being further shaped, such apaperboard-type material as well as plastics.

Many embodiments of the container 20 will involve either a 2 blankmanufacturing process (See FIG. 4 a) that comprises a top blank 100comprising the entire surface of the container 20 except for the bottomblank 102 which comprises the bottom surface 48 and/or base 40 of thecontainer 20.

Other embodiments will involve a 3 blank configuration (See FIG. 4 b),with a lid blank 104 and a sidewall blank 106 comprising the portions ofthe container that would be comprised of the top blank 100 in a 2 blankconfiguration.

In different embodiments of the container, different processes can beperformed on the container 20 when it is in the form of blanks, whileother processes are performed after the blanks have been fused togetherand/or shaped at least partially into the form of the container. In manyembodiments of the container, the primary score line 61 is not machinedinto the top blank 100 (2 blank configuration) or onto the sidewallblank 106 (3 blank configuration) until after the applicable blank hasalready been shaped around the bottom blank 100. By machining theprimary score line 61 (which is the substantially horizontal score linewhich comprises the body hinge 56 and the inner groove 52) after theblanks have been shaped, the primary score line 61 can maintain asubstantially circular shape and the overall structural integrity of thecontainer 20 is enhanced. In some embodiments, the primary score line 61can be machined directly into the applicable blank. In still otherembodiments, multiple elements can be machined into a substantiallyshaped container 20 rather than the flat blanks.

B. Blank Preparation

Paperboard blanks can be prepared in a variety of different ways thatinvolve either punching or cutting a roll of material such as paperboardor plastic. Blanks can be formed from a roll that is subject to acoating/lamination process to reinforce certain areas of the container20, a print process for displaying indicia such as words or graphics onthe container 20, a slitting process, and then a blanking or punchingmachine that results in the prepared blanks. Many paperboard embodimentsof the container 20 can be machined from either pre-printed, pre-punchedblanks, and/or optional pre-printed roll stock

A variety of different machines can be used to actually cut or punch theblanks. Rotary dies, RP rotary dies (which is sometimes referred to ascrossover technology), steel-rule die cutting, solid steel blankingdies, and other suitable machines can be used. It is often desirable toavoid using tools that avoid metal to metal contact that provide a cleancut, eliminating the standard crush-type cut. Thus RP rotary dies (whichcan also be referred to as “Bernal” rotary dies) are often desirable.Use of a shear-type cut can reduce or eliminate chaff, slivers, raggedcuts, and other undesirable outcomes that result from a more punch-typeapproach.

Many manufacturers prefer solid-steel blanking dies however tools arenot well suited in many embodiments of the container 20 for embossing,forming, and creasing/folding elements into the container 20. Thequality of the cut and the defects in the printing/blanking webregistration can shut down a manufacturing process and render themachining of the container 20 with the use of a solid-steel blanking dieimpracticable in some but not all embodiments of the container 20.

C. Blank Fusing

Many different machines can be used in the process of fusing the blankstogether and shaping the container 20. Roll stands, printers, rollfeeders, heating applications, pressure applications, foldingapplications, and other tools can be used to fuse the blanks together.In a 3 blank embodiment, the lid blank 106 and the sidewall blank 104are typically fused together before any shaping occurs. The fusing ofblanks with the bottom blank 102 typically occurs simultaneously withthe shaping of either the top blank 100 or the sidewall blank 106 thathas already been fused to the lid blank 104.

D. Forming/Shaping

A variety of different tools and processes can be used informing/shaping the container 20.

Blank feeders, transfer turrets, shuttle table, hoppers, timing belts,bottom feeders, forming stations, mandrel turrets, bottom reformers,sealers, pre-heaters, heating stations, incurl stations, top curlstations (in some instances 3 top curl stations are used), finishingstations, rimming turrets, folding stations, tamper/lubricatingstations, folding plates, clamping bars, shell distributors, rotatingnozzles, calibration stamps, vacuum nozzles, and other devices are usedto shape either the top blank 100 or the fused blank (comprising thesidewall blank 106 and the lid blank 104) around the bottom blank 100.

Blanks can be precisely positioned and tightly wrapped around thefolding mandrel. The design of some cup embodiments of the container 20allows for the body 22 wrapping with the punched and drawn cup bottominserted prior to sidewall sealing or optional insertion of the cupbottom after the side wall sealing. Sealing of the side-seam and bottomseam can be completed by utilizing flame, hot air or ultrasonic heating.Sealing parameters related to temperature, pressure and registration areimportant within the forming process. The container shells (the shapedcontainers 20) can be designed to facilitate easy transfer betweenmultiple turret stations positioned on the cup forming machine.

E. Post-Shaping Processing

In many embodiments of the container 20, there are processes performedon the container 20 after the container 20 is fully shaped. For example,it is often desirable for the process of top curling the rim 34 (whichin some instances can involve 3 iterations of curling stations) and themachining of the loop 61 can both be done after the container 20 isfully shaped.

The partially finished container 20 can be transferred to the top curlturret, incorporating multiple stations to form the top curl rim 34,lubrication, pre-curl, finishing curl and calibration.

F. Manufacturing Method Example #3

FIGS. 4 a and 4 b provide two examples of a method for manufacturing acontainer 20. FIG. 10 a provides a third example.

At 300, blanks are cut. This typically involves a rotary die or an RProtary die. The number of configurations of blanks cut per container 20can vary from embodiment to embodiment.

At 302, a sidewall blank 106 can be top load fed onto a continuousmotion conveyer. This can include a rotary pick and place feeding modulethat is seamlessly integrated with the container 20 forming machine. Thesidewall blanks 106 can pass through the rotary pick and place modulethat includes lid hopper stations where the rotary pick motion can placethe lid blank 104 in alignment with the sidewall blank 106.

At 304, the side wall blank 106 is fused to the lid blank 104. Thisprocess can include low-density polyethylene heating and pressuretechnology. For container 20 embodiments involving cups for hotbeverages, the inner surface of the sidewall blank 106 can be lined witha thin layer of polyethylene on the top and bottom surfaces. When thesidewall blank 106 and the lid blank 104 are fused together, theaggregate package structure can have greater strength and stability. Theuse of separate lid blanks 104 and sidewall blanks 106 has severaladvantages, including: (1) lid 28 staining/wicking; (2) cup stackingafter filling; (3) strengthening the lid 28 generally and againsthumidity specifically; and (4) reduction of waste/scrap because moreaggregate containers 20 can be fit into less roll sheets.

At 306, the fused blank is shaped into a shell around the bottom blank102. This process usually involves both heat and pressure.

At 308, the bottom blank is secured within the bottom portion of theshell (either the shaped top blank 100 or the fused lid blank 104 andsidewall blank 105).

At 310, the primary score line 61 is machined into the container 20.This step can be immediately preceded but is typically followed by thecurling of the rim 34. In some embodiments, three top curl stations canbe used to curl the rim 34.

Then the process ends.

G. Manufacturing Method Example #4

FIG. 10 b is a flow chart diagram illustrating an example of a processthat can be used to manufacture the container 20.

At 320, the bottom blank 102 is heated. This can involve the use amandrel turret to index the bottom blank 102 into a bottom re-formerstation where the bottom skirt is heated and re-formed into a shape moresuitable for wrapping.

At 322, the edges of the top blank 102 or a fused blank (the sidewallblank 106 and the lid blank 104) are heated. This can be accomplishedthrough the use of a transfer turret that indexes the sidewall blank 106into a sidewall sealer and bottom preheat station where the edges of theblanks 104 and 106 are heated in preparation of the shell forming.

At 324, the top/fused blank is wrapped around the bottom blank 100forming a shell. This can be accomplished using a transfer turret toindex the sidewall blank 106 into the folding station, releasing theblank after the lower clamp clamps the blank against the mandrel. Themandrel turret can index the bottom blank 102 into the folding station.The folding wings can wrap the sidewall blank 106 around the bottomblank 102, forming the cup shell. The mandrel turret can then index theshell to the bottom heat station.

At 326, the bottom area of the shell is heated. This can involve heatingthe inside skirt of the bottom blank 102 and transporting the shell tothe bottom incurl station.

At 328, the bottom blank 102 is heated.

At 330, bottom blank 102 is moved downward in the shell.

At 332, lubricant (typically vegetable oil) is applied to the outside ofthe shell.

At 334, the bottom edge of the shell is curled over the bottom skirt ofthe bottom blank 102. This can be done through the use of a bottomincurl station where the bottom edge of the sidewall blank 106 is curledover the bottom skirt of the bottom blank 102.

At 336, the bottom is finished, knurled, and squared. A mandrel turretcan index the shell to the bottom finishing station where this processis performed.

At 338, the shell is moved pneumatically. This can be done using amandrel turret that indexes the shell to the rimming turret, where theshell is pneumatically removed from the mandrel and transferred to therimming turret.

At 340, the shell is pushed down a pocket 340. The shell is indexed fromthe rimming turret to the tamper/lubricator station.

At 342, lubricant is applied to the top of the shell.

At 344, the first curl is applied to the top of the shell. In someembodiments, there can be three iterations of curling the rim 34 beforethe rim 34 is finished.

At 346, the rim 34 is finished.

At 348, the primary score line 61 comprising a body hinge 56 and aninner groove 52 are formed in the container 20.

Then the process ends.

H. Manufacturing Method Example #5

FIG. 10 c is a flow chart diagram illustrating an example of a processfor manufacturing the container 20.

At 350, the fused blanks (blanks 104 and 106) are fanned. This caninvolve jacket blanks (segments) that are placed in a blank hopper withthe printed side facing down. The segments are fanned using an air blastto prevent sticking

At 352, the fused blank is pre-folded. Pre-folding can be applied to theside of the blank that lies inward after being rolled.

At 354, the fused blank is heated. The seam surface of the fused blankcan be heated at the same time in which the pre-folding process at 352is performed since the two dies of the blank are different.

At 356, the fused blank is subjected to a final folding process. Thisoccurs before the clamping bar closes on the side seam area.

At 358, the bottom blank 102 is positioned with respect to the fusedblank. The shell is taken off the folding turret in an upper verticalposition. The clamping bar opens and the pusher moves the shell off thefolding mandrel. The shell is then moved to the shell distributor.

At 360, the bottom portion of the fused blank is heated and the bottomblank 102 is heated. This occurs after the container 20 bottom isbrought together with the shell.

At 362, the bottom shell is incurled and sealed into the shell of thefused blank.

At 364, lubricant is sprayed by a rotating nozzle to aid the top curlprocessing.

At 366, the upper edge of the container 20 is preformed. This willultimately become the rim 34.

At 368, the rim 34 is curled. The process can involve multiple curlprocesses. In some embodiments, there are three top curl stations forcurling the rim 34.

At 370 the container 20 is calibrated using a calibration stamp.

At 372, the primary score line 61 is machined into the container 20. Asdiscussed above this involves the inner groove 52 and the body hinge 56.In many embodiments, the primary score line 61 is circular orsubstantially circular in shape while the container 20 is in an openposition.

Then the process ends.

X. TOOLING AND MANUFACTURING METHOD

As with any product, the design features of the container 20 areimpacted by the manufacturing process and tooling used to manufacturethe container. The process can be performed using a variety of differentmachine tools known in the prior art. In a preferred embodiment,containers are produced using machine tools substantially similar tothose of the prior art. In particular, the infrastructure below thetable need not be changed in order to support some relatively modestfunctionality modifications above the table.

FIG. 10 h is a diagram illustrating an example of a machine toolconfiguration 500 and various tool components that can be used tomanufacture the container 20. FIG. 10 d is a flow chart diagramillustrating an example of a process flow for manufacturing thecontainer 20 that utilizes the tool configuration 500 illustrated inFIG. 10 h. Thus FIGS. 10 h and 10 d relate to each other.

Steps 400 through 430 can be performed using a blank feed paper cupmachine. Steps 432 through 460 can be performed using a tab lidapplicator machine. The various tooling components/stations machinesthat can be used to manufacture the container 20 are collectivelyreferred to as a tool 500.

At 400, the bottom blank 102 is cut using a bottom maker tool component524. FIG. 5B illustrates an example of a bottom blank 102. The shape ofthe bottom blank 102 will depend on the shape of the bottom 40 portionof the container 20. In many instances, the bottom blank 102 will becircular shaped, but other geometric shapes are possible.

At 402, the side wall blank 106 is fed into the tool using a blankconveyer tool component 520.

At 404, the side wall blank 106 is transferred using a blank transferturret tool component 522.

At 406, the edges of the side wall blank 106 are heated and reformedusing a sidewall sealer 523. This is done to facilitate forming a shall108 (mating one edge of the sidewall blank 106 with itself) out of theside wall blank 106 (in alternative embodiments involving only 2 blanksinstead of 3, the top blank 100 is substituted for the sidewall blank105 throughout this process) as well as to facilitate bonding with thebottom blank 102. In an embodiment of the container 20 that involves abottom 40 elevated off the ground by a circular ring base, the bottomblank 102 is shaped into that base.

At 408, the sidewall blank 106 is wrapped around the shaped bottom blank102 on the sidewall sealer 523. The contact areas of both have beenpre-heated at 404. FIG. 10 e illustrates an example of a sidewall blank106 being wrapped around the shaped bottom blank 102.

At 410, the bottom seal area of the shell 108 is heated by a firstbottom heat station 518. At 412, the bottom seal area of the shell 108is heated a second time by a second heat station 516.

At 414, the bottom edge of the sidewall blank 106 is curled over thebottom blank 102 skirt (the circular ring forming the future base of thecontainer 20). This is done using a bottom incurl station 515. FIG. 10 fillustrates an example of a curled edge at the skirt.

At 416, the bottom 40 is finished, knurled, and squared using a bottomfinish station 514. The bottom is comprised of the bottom blank 102 andthe fused areas of the sidewall blank 106 that are permanently matedtogether. FIG. 10 g illustrates an example of a bottom 40 that isfinished, knurled, and squared.

At 418, the shell 108 is moved. This is preferably done pneumatically(air suction/vacuum) although other techniques could also be utilized.At 420, the shell 108 is then pushed down a “female” pocket to securethe shell 108 for the next step in the process.

At 422, a tamper lubricator 525 applies lubricant to the top of theshell 108 to prepare for curling the rim 34 of the container 20. In someembodiments, the rim 34 is curled twice (curled then finished). In otherembodiments, the rim 34 is curled three times (curled, finished, andcalibrated).

At 424, the first curl is applied by a first rim curl station 526.

At 426, the second curl is applied by a second rim curl station 529.

At 428, the third curl (which is optional) is applied by a third rimcurl station 531. The rim 34 is referred to above and illustrated inFIGS. 8 a-8 g.

At 430, the shell is moved pneumatically to the next step in theprocess, moving the shell 108 from the blank feed paper machine (steps400-430) to the tab lid applicator machine (steps 432-462).

At 432, the shell 108 is turned 180 degrees using an inverter turret532. At 434, the shell 108 is pneumatically moved. At 436, the shell 108is pushed down “female” pocket for subsequent processing.

At 438, a tamper station 513 is used to apply lubricant in the shell108.

At 440, the first grooving of the primary score line 61 is performed bya first grooving station 512. At 442, the second grooving of the primaryscore line 61 is performed by a second grooving station 510. The scoreline 61 is formed around the circumstance of the container 20. Thegrooving of both stations 512 and 510 is done while the container 20remains secured within the female pocket of the turret machine. The loop61 is comprised of the body hinge 56 and the inner groove 52 arediscussed above, and illustrated in FIGS. 7 a-7 d and FIGS. 8 a-8 f.

At 444, an orientor 509 is used to orient the shell 108 for subsequentprocessing.

At 446, a lid hole die 502 is used to punch a hole in the lid stock forthe subsequent creation of the lid blank 104.

At 448, a tab 30 is attached to the lid stock by a label applicationarea 503.

At 450, a lid scoring die 505 is used to score the lid stock.

At 452, a lid blanking die 506 is used to cut the lid blank 104 from thelid stock.

At 454, a lid transfer turret 507 is used to transfer the lid blank 104for mating the lid blank 104 with the shell 108

At 456, a lid heater 508 is used to heat the lid blank 104 to preparefor mating the lid blank 104 with the shell 108.

At 458, the shell 108 is heated to prepare the shell 108 for mating withthe lid blank 104.

At 460, a lid sealing clamp 533 is used to fuse the lid blank 104 to theshell 108.

At 462, a container blow off tool 533 is used to pneumatically move thefinished container 20.

The process then ends, and the container 20 awaits subsequent shippingto customers.

X. INDEX OF ELEMENTS/ELEMENT NUMBERS

Different embodiments of the container 20 can involve differentcombinations and configurations of components and subcomponents. Most ofthe claim elements below in Table 1 below are optional, and suchelements may be totally absent from particular embodiments of thecontainer or even entire container categories.

TABLE 1 Index of component element numbers Element Number NameDescription/Comments 20 Container A device that has the capacity tocontain contents. Examples of containers include cups, such as coffeecups, other forms of non-aseptic cups, aseptic cups, or a virtuallylimitless variety of other containers (including but not limited tocontainers that have nothing to do with food or beverages). Differentembodiments of the container can be comprised of different materialcompositions and different component and subcomponent configurations.All containers 20 must include a body 22 and a lid 28. All othercomponents are potentially optional, depending on the particularembodiment of the container 20. 22 Body A portion of the container 20that includes the cavity 46. The body 22 is the portion of the container20 that moves the least when the container 20 changes from an operatingstate of open to an operating state of closed, and vice versa. 23Reinforcement A surface area that is part of the lid blank 104 that isMember connected to and reinforces the portion of the sidewall blank 106that becomes the plate 24. 24 Plate A portion of the container 20 thatacts as an interface between the lid 28 (which is used to open and closethe container 20) and the body 22 (which provides for the cavity 46 andthe capability of “containing” something). 25 Vertical Crease Straightscore lines on the lid 28 used to reinforce the lid 28. 26 Plate Hinge Ahinge between the plate 24 and the lid 28. The plate hinge 26 helpsfacilitate the transition of the lid 28 from an operating status of opento an operating status of closed, and vice versa. Embodiments of thecontainer 20 that do not include a plate 24 do not include a plate hinge26. 27 Cover A surface area 27 that covers the passageway 32. In someembodiments of the container 20, the tab 30 is the cover 27. In otherembodiments, the cover 27 is separate and distinct from the tab 30 ofthe container 20. 28 Lid A moveable surface that is capable of sealingthe cavity 46, and closing the container 20. The movement of the lid 28is what changes the operating state of the container 20 between a stateof being open and a state of being closed. 29 Gaps Small openings inreinforcement member 23 of the lid blank 104 that can serve ashorizontal ventilators for the container 20. 30 Tab A portion ofmaterial connected to the lid 28 that can be pulled by a user to openthe container 20. In some embodiments, the tab 30 is used to seal orunseal a passageway 32 in the lid 28 of the container 20. In otherembodiments, the tab 30 is totally unrelated to the opening or closingof the passageway 32. 31 Dimple An extrusion extending outward or inwardfrom the external surface of the container 20. A dimple 31 can be formedby embossing, debossing, or some other process. Dimples 31 can provide avariety of functions that enhance the ability of users to grasp or usethe container or to insulate a user from the temperature of the contentswithin the container 20. For example, dimples 31 can be serve as a builtin sleeve for a coffee cup, allowing the drinker to hold a cup of hotcoffee without any intervening sleeve. 32 Passageway An opening in thecontainer 20 that is typically located (“opening”) in the lid 28. Inmany embodiments the passageway 32 can be opened or closed while the lid28 remains in a closed position. For example, the passageway 32 in thecontext of a cup can be used to drink from the cup even though the lid28 is in a closed position. Liquid in the cup can pass through thepassageway 32 directly or through a straw placed within the passageway32. The passageway 32 can also be referred to as an opening. 33 DimpleGroup A grouping of individual dimples 31. 34 Rim An upper edge of thebody 22 of the container 20. The (“top curl”) rim 34 can also bereferred to as a top curl. In many instances, the rim 34 is a reinforcedexterior surface representing the highest vertical position of the body22. The horizontal plane of the rim 34 is often substantially parallelto the lid 28 when the lid 28 is in a closed and sealed position. Thehorizontal plane of the rim 34 is also often substantially parallel tothe base 40 of the body 22. 36 Headwall A portion of the body 22 that isbelow the rim 34 but (“head-wall” or above the substantially horizontalscore line 61 (the “head wall”) score line that can comprise the bodyhinge 56 and the inner groove 52). The head wall 36 (which can also bereferred to as a headwall 36). 38 Support score Score lines in the body22 of the container 20 that lines structurally support the lid 28 andplate 24 (if present). Support score lines 38 can be oriented in ahorizontal manner or in a vertical manner. Support score lines 38 can bereferred to as “plate support score lines” in embodiments where locatedbelow the plate 24 and “lid support score lines” in embodiments wherethere is no plate 24. 39 Bottom interior An internal surface in thecontainer 20 that is the surface bottom of the cavity 46. The bottominterior surface (“Interior 39 is often substantially flat andsubstantially parallel Base”) with the ground when the container 20rests on a flat surface. In some embodiments, the interior base 39 iselevated to further separate the contents of the container 20 from thesurface on which the container 20 rests. 40 Bottom exterior An exteriorsurface at the bottom the container 20. In surface many embodiments, thebottom 40 is substantially flat. (“Exterior In embodiments of thecontainer 20 in which the Bottom”) interior base 39 is elevated, theexterior bottom 40 may be in the shape of circular ridge, circular ring(i.e. skirt) or some other hollow geometric shape. 41 Rim Arc An anglerepresenting the magnitude of the rim 34 with respect to a horizontalcross section of the container 20. 42 Wall The exterior surface of thebody 22 that surrounds (except for the opening sealed by the lid 28) thecavity 46. Different embodiments of the container 20 can involvesingle-layered walls 42 or multiple-layered walls 42. 44 Interior wallThe interior surface of the body 22 that surrounds (except for theopening sealed by the lid 28) the cavity 46. 45 Hinge break A break inthe plate hinge 26 or body hinge 56. The hinge break 45 can assist thetransition of the lid 28 between different operating states. 46 CavityAn empty space within the container 20 that can be used to hold orcontain the contents of the container 20. In many instances, thegeometric shape of the cavity 46 will generally resemble the geometricshape of the container 20 itself. However, some embodiments of thecontainer 20 may involve vastly different geometric shapes than thecavity 46 within the container 20. 48 Tab Base Score A score line at thebase of the tab 30. line 49 Chevrons A score line in the lid 28.Chevrons 49 can serve to enhance the structural stiffness of the lid 28as it transitions between operating states and as the container 20 ismoved around with contents enclosed. 50 Passageway A score line used toopen or close the passage 32. Score line 51 Lid edge The edge of the lid28 that serves to seal the container (“edge”) 20 in a closed position.The edge 51 is lodged within the inner groove 52 of the body 22 when thelid 28 is in a sealed position. 52 Inner groove An indentation withinthe interior surface of the body 22 that is used to secure the edge 51of the lid 28 when the lid 28 is in a closed position. 53 Exteriorfacing The exterior facing side of the inner groove 52. The inner groovespace between this score line 53 and the rim 34 is the headwall 36. 54Flaps A surface connected to the plate 24 or in certain embodiments, thelid 28. Flaps 54 may also be connected to the body 22. Flaps 54 canassist in the motion of the lid 28 from an open position to a closedposition. Flaps 54 can also help keep the lid 28 in a sealed and lockedposition. 55 Side score line A score line connecting a flap 54 to theplate 24 (or in some instances, the lid 28). 56 Body hinge A score line56 on the body 56 used to assist in the motion of the lid 28 betweenopen and closed positions. The body hinge 56 separates the body 22 fromthe plate 24 in embodiments of the container 20 that include a plate 24.Otherwise, the body hinge 56 separates the body 22 from the lid 28. 57Flap bottom If a flap 54 is connected to the body 22, the flap bottomscore line score line 57 is the score line that connects the flap 54 tothe body 22. 58 Skid locks A protrusion outward from the plate 58 thatenhances the ability of users to stack containers 20 in a closedposition. Skid locks 58 can be in a variety of different geometricshapes, including circles, squares, rectangles, ovals, etc. as well asirregular shapes. 59 Flange A projecting collar that can assist in thesealing of an aseptic container 20, or in other types of containers 20as desired. 60 Third Tab A score line within the tab 30 or within asurface Score Line blocking the passageway 32. This score line 60 can bepushed inward towards the cavity 46 to clear the passageway 32. 61 LoopA score line running substantially around the parameter (“primary scoreof the container 20. The loop 61 can include the body line”) hinge 56and the inner groove 52. 63 Stiffener score A curved score line in thelid 28 used to reinforce the line structural integrity of the lid 28.Lid stiffener score lines 63 are substantially in the shape of the edge51. 64 Inner groove The angle of the indentation comprising the innerangle groove 52. The inner groove angle 64 can vary widely in differentembodiments of the container 20. 70 Score Lines A seam or fold in thecontainer 20. Some score lines 70 are foldable score lines 71 that willfold to varying degrees in the opening and closing of the lid 28. Otherscore lines 70 non-foldable score lines 72 are not adapted to be foldedand are otherwise not related to opening and closing of the lid 28. 71Foldable Score A score line 70 that provides for bending or folding inLines the opening and closing of the lid 28. Examples of foldable scorelines 71 include the body hinge 56, the plate hinge 26, the side scorelines 55 (if any), and the flap bottom score lines 57(if any). 72Non-Foldable A score line 70 is not directly involved in the openingScore Lines and closing motion of the lid 28. Non-foldable score lines72 serve the enhance the structural strength of different surfaces 75 onthe container 20. Examples of non-foldable score lines 72 includevertical creases 25, the rim 34, support score lines 38, the tab scoreline 48, chevrons 49, the inner groove 52, the exterior face of theinner groove 53, the tab score line 60, and the stiffener score line 63.75 Surface A surface 75 on the container 20. The container 20 can bedivided up primarily into surfaces 75 and score lines 70. 77 InsulationA layer of material that can be positioned vertically Layer beneath thelid 28 and/or plate 24. The purpose of the insulation layer 77 is toinsulate the lid 28 from the heat of a hot beverage. The insulationlayer 77 can in some embodiments be comprised of a plastic or foam thatsimilar in feel and texture to bubble wrap. 79 Circular Arc The plate24, side flaps 54, and side score lines 55 can be shaped in such amanner such that the edges of the lid 28 and plate 24 form a continuouscircular arc 79 that is interrupted only by the plate hinge 26. 90 Stack(closed) A collection of containers 20 in closed positions placed on topof each other. 94 Stack (open) A collection of containers 20 in openpositions placed on top of each other. 97 Flap Angle An angle formedbetween the side score line 55 and the bottom score line 57. 100 Topblank A blank used to form the entire container 20 except for the bottomsurface of the container 20. 102 Bottom blank A blank used to form thebottom surface 40 of the container 20. A two blank embodiment of thecontainer 20 can be formed using the top blank 100 and the bottom blank102. A three blank embodiment of the container 20 can be formed using abottom blank 102, a lid blank 104, and a sidewall blank 106. 104 Lidblank A blank used to form the lid 28 of the container 20. Someembodiments of the lid blank 104 can include 106 Sidewall blank A blankused to from the portions of the container that are not the lid 28 andnot the bottom surface 40. 108 Shell A sidewall blank 106 that has beenfused to a bottom blank 102. 500 Tool Machine for fusing the lid blank104 to the sidewall blank 106.

XI. ALTERNATIVE EMBODIMENTS

The container 20 can be implemented in a wide variety of differentembodiments, configurations, and contexts. In accordance with theprovisions of the patent statutes, the principles and modes of operationof this invention have been explained and illustrated in a variety ofembodiments and configurations. However, it must be understood that thisinvention may be practiced otherwise than is specifically explained andillustrated without departing from its spirit or scope. The containerand methods for using the container can be implemented in a wide varietyof different components, component configurations, and componentcompositions.

1. A container, comprising: a plurality of score lines, said pluralityof score lines including a plurality of foldable score lines, saidplurality of foldable score lines comprising a body hinge, a platehinge, a plurality of side score lines, and a plurality of flap bottomscore lines, said plurality of side score lines including a first sidescore line and a second side score line, said plurality of flap bottomscore lines including a first flap bottom score line and a second flapbottom score line; and a plurality of surfaces, said plurality ofsurfaces including a body, a plate, a lid, and a plurality of flaps,said plurality of flaps including a first flap and a second flap;wherein said plate is substantially encircled by said body hinge, saidplate hinge, and said plurality of side score lines; wherein said platehinge connects said plate to said lid; wherein said body hinge connectssaid body to said plate; wherein said plurality of side flaps connectsaid plurality of flaps to said plate; and wherein said plurality offlap bottom score lines connect said flaps to said body.
 2. Thecontainer of claim 1, further comprising a plurality of dimples, whereinsaid plurality of dimples are positioned on said body.
 3. The containerof claim 2, wherein said plurality of dimples are two-sided dimples. 4.The container of claim 1, wherein said body is curved, wherein said lidis curved, said container further comprising a loop, said loop includinginner groove and said body hinge.
 5. The container of claim 1, said lidincluding an insulation layer comprised of a heat laminated foam.
 6. Thecontainer of claim 5, where said plate also includes said insulationlayer of said heat laminated foam.
 7. The container of claim 1, whereinsaid container is comprised of paperboard.
 8. The container of claim 1,wherein said plate is a doubled layered plate created by bonding a lidblank that includes a reinforcement member to a sidewall blank thatincludes said plate.
 9. The container of claim 8, wherein saidreinforcement member includes a ventilation gap.
 10. The container ofclaim 1, said plurality of score lines further including a plurality ofnon-foldable score lines, said plurality of non-foldable score linesincluding a first non-foldable score line on said body, a secondnon-foldable score line on said plate, and a third non-foldable scoreline on said lid.
 11. The container of claim 10, wherein said pluralityof non-foldable score lines includes at least one non-foldable scoreline that is substantially vertically oriented and at least onenon-foldable score line that is substantially horizontally oriented. 12.The container of claim 1, wherein said plate and said lid form acontinuous circular arc when said lid is in a closed position.
 13. Thecontainer of claim 1, wherein said plate hinge is not straight andwherein said plate hinge includes a hinge break.
 14. The container ofclaim 1, said body including a rim that is positioned vertically above:(a) said body hinge; (b) said plate hinge; and (c) said lid when saidlid is in a closed position.
 15. The container of claim 1, wherein saidbody is curved and wherein said lid is curved.
 16. The container ofclaim 1, wherein said body hinge is folded and unfolded to a greaterdegree than said plate hinge in the opening and closing of said lid to asubstantially greater magnitude than said plate hinge in the opening andclosing of said container.
 17. A container, comprising: a platesubstantially surrounded by a plurality of foldable score lines, saidplurality of foldable score lines including a body hinge, a plate hinge,and a plurality of side score lines, said plurality of side score linesincluding a first side score line and a second side score line; a lidconnected to said plate by said plate hinge, said lid including a curvededge; an insulation layer positioned underneath said lid and said plate;a body connected to said plate by said body hinge, said body includingan inner groove for securing said curved edge of said lid when said lidis in a closed position, said body further including a plurality ofdimples; and a plurality of flaps connected to said body, said pluralityof flaps including a first flap connected to said plate by said firstside score line and a second flap connected to said plate by said secondside score line; a plurality of flap bottom score lines connecting saidbody to said flaps, said plurality of flap bottom score lines includinga first bottom score line connecting said first flap to said body and asecond bottom score line connecting said second flap to said body. 18.The container of claim 17, wherein said body is curved, wherein said lidincludes a curved edge, said body including a curved rim and a curvedinner groove, wherein said curved rim is above said curved inner groove,and wherein said curved rim is parallel to said curved inner groove. 19.The container of claim 18, wherein said rim is a triple-curled rim, andwherein said plate is part of a side wall blank that is mated to areinforcement member of a lid blank, wherein the dimensions of saidreinforcement member are substantially identical to the dimensions ofsaid plate, and wherein said reinforcement member is positioned belowsaid plate and above said insulation layer when said lid is in a closedposition.
 20. A method for opening a curved container, comprising:pulling on a tab attached to a lid on the container; and folding aplurality of foldable score lines in opening the lid, said plurality offoldable score lines including a plurality of hinges positioned betweenthe lid and body of the container.